Thermal Wall Anchor with Insulating Coating

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Solution Overview

Problem

Anchoring systems for cavity walls, primarily made of metal components, create thermal bridges that lead to heat transfer and energy losses, while completely non-conductive systems are structurally weak.

Innovation Solution

A thermal wall anchor with a metal body coated to reduce thermal conductivity, featuring a driven end and a driving end with a barrel portion, where the thermal coating significantly lowers the K-value of the anchor, providing both strength and thermal isolation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metal components are used in the anchoring system, then structural strength is improved, but thermal conductivity increases causing heat transfer losses

Engineering Contradiction:
Improvestructural strengthVSAvoidheat transfer losses
Core Design Contradiction:
StrengthVSLoss of energy

Solution Approach 1:

The anchoring system uses a composite structure combining metal components with thermally insulating materials. The metal provides structural strength while the insulating material (such as foam or air gaps) reduces thermal conductivity, creating a composite anchoring element that addresses both strength and thermal performance requirements simultaneously.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

A thermally insulating intermediary material is introduced between metal components that would otherwise create thermal bridges. This intermediary layer (such as insulation material or air spaces) breaks the thermal pathway while allowing the metal components to maintain their structural function, thereby reducing heat transfer losses without compromising strength.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Loss of energy

If completely thermally-nonconductive materials are used in the anchoring system, then heat transfer is reduced, but structural strength decreases

Engineering Contradiction:
Improveheat transfer lossesVSAvoidstructural strength
Core Design Contradiction:
Loss of energyVSStrength

Solution Approach 1:

The solution employs composite anchoring elements where thermally-nonconductive materials (such as foam, plastic, or air-filled structures) are combined with metal components. The nonconductive material provides thermal isolation while the metal portions maintain necessary structural strength, achieving both thermal performance and mechanical reliability.

Inventive Principle:
Principle #40Composite materials

Solution Approach 2:

The anchoring system is segmented into distinct functional zones: metal portions that provide structural strength and thermally insulating portions that reduce heat transfer. This segmentation allows each material to perform its optimal function without the drawbacks of using a single material for the entire anchoring element.

Inventive Principle:
Principle #1Segmentation

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 thermal coating reduces the U-value of the cavity wall by 5-80%, minimizing heat transfer and maintaining structural integrity, while being fire-resistant and non-toxic.

Implementation Method 1

A thermal coating is disposed on the driven end portion and the first end of the barrel portion. The thermal coating is configured and arranged to reduce thermal transfer in the cavity wall between the elongate body and the inner wythe when installed.

Methodology Applied
Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS9758958B2Thermal wall anchor
Publication Date: 2017.09.12 HOHMANN & BARNARD INC
  • US9758958B2 patent drawing
  • US9758958B2 patent drawing
  • US9758958B2 patent drawing

AI summary

A wall anchor for use in a cavity wall includes an elongate body having a driven end portion and a driving end portion. The driven end portion is adapted to be threadedly mounted on the inner wythe of the cavity wall. The elongate body includes a barrel portion adjacent the driven end portion. A first end of the barrel portion is adapted to abut the inner wythe of the cavity wall when installed. A thermal coating is disposed on the first end of the barrel portion. The thermal coating is configured and arranged to reduce thermal transfer in the cavity wall between the elongate body and the inner wythe when installed.