Wall Fastener Shank Thermal Break Design
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Solution Overview
Problem
Conventional brick anchors fail to provide effective thermal insulation, reduce damage to insulation and air barriers during installation, and do not offer improved fire performance in masonry cavity walls with air gaps.
Innovation Solution
The development of wall fasteners with a non-metallic tubular shank and large diameter washers that create a thermal break, compress insulation for sealing, and include a masonry tie for secure retention, along with a wedge seal for enhanced water resistance, preventing direct metal-on-metal contact and allowing for fire-resistant performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metal brick anchors are used to secure masonry veneer to the wall, then the anchor provides strong mechanical retention, but direct metal-on-metal contact creates thermal bridging that reduces thermal insulation performance
Solution Approach 1:
The patent introduces a non-metallic shank (polymer or plastic material) as an intermediary between the metal screw head and the masonry veneer tie. This non-metallic shank replaces direct metal-to-metal contact, eliminating thermal bridging while maintaining mechanical fastening function. The non-metallic material acts as a thermal break, preserving insulation performance between the interior and exterior of the wall assembly.
Solution Approach 2:
The anchor assembly uses composite construction combining metal components (screw head, washer) with non-metallic shank material. This composite approach allows the metal parts to provide structural strength and the non-metallic shank to provide thermal insulation, achieving both mechanical retention and thermal break functionality in a single integrated fastener system.
2Productivity
If conventional brick anchors are installed by spinning during installation, then the anchor can be quickly secured to the wall, but the spinning action causes significant damage to the insulation and air barrier materials
Solution Approach 1:
The fastener is segmented into a separate shank portion and head portion, allowing the head to be driven into the wall without rotating the entire fastener. The shank remains stationary while the head is secured, eliminating the spinning action that damages insulation and air barriers. This segmentation enables direct driving installation similar to conventional screws without the harmful rotational effects.
3Strength
If conventional metal anchors are used in masonry cavity walls, then the anchor provides structural support, but the metal components can melt or deform in fire conditions, compromising anchor retention
Solution Approach 1:
The anchor assembly combines metal components for structural strength with non-metallic shank material that resists fire damage. The non-metallic shank maintains its integrity in fire conditions where metal would melt or deform, ensuring continuous anchor retention. The metal washer and screw head provide the necessary clamping force while the non-metallic shank survives fire exposure.
Solution Approach 2:
The non-metallic shank acts as a fire-resistant intermediary between the metal fastening components and the masonry veneer. In fire conditions, this non-metallic material maintains its physical properties while metal components would fail, serving as a protective mediator that preserves the anchor's retention function during fire exposure.
4Device complexity
If conventional brick anchors are used without compression features, then the installation is simple, but air and water leakage can occur at the penetration points through the insulation and air barrier
Solution Approach 1:
The washer is designed with a compressed thickness parameter that is less than the thickness of the insulation layer. This parameter change allows the washer to compress the insulation material when installed, creating a sealing effect that prevents air and water leakage at the penetration points. The compression transforms the insulation from an uncompressed state to a compressed sealing state.
Solution Approach 2:
The non-metallic shank and compressed washer design provides beforehand cushioning by compressing the insulation and air barrier materials during installation. This pre-compression creates a seal that prevents future air and water infiltration, protecting the wall assembly from harmful leakage before environmental exposure occurs.
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 solution provides improved thermal insulation, reduced damage to insulation and air barriers, and enhanced fire resistance by maintaining anchor retention even if the non-metallic components melt, ensuring air and water tightness.
Implementation Method 1
exemplary embodiments provide a thermal break, such that there is no direct metal-on-metal contact, which reduces energy transfer through insulation positioned between an exterior wall covering and an air barrier covered inner wall
Implementation Method 2
large diameter washers may be configured to affix to the insulation and may also compress the insulation at the point of fastener shank penetration, and thus effectively provide a 'gasket' against air and water leakage
Data Source
AI summary
A wall fastener assembly for retaining an exterior wall covering alongside a wall includes a screw, an elongated shank and a washer. The shank is configured to provide a space for a layer of insulation between the exterior wall covering and the wall. The shank comprises a center bore extending along the length of the shank for receiving the screw configured to secure the wall fastener assembly to the wall. The shank also includes a pair of flanges positioned opposite the wall. The pair of flanges form a groove between them. The groove configured to receive a masonry tie, wire tie or a girt track. The washer includes a central portion comprising a center hole for receiving the shank. The wire tie includes a narrow portion configured to be retained by the groove. A seal may be provided on the shank to seal the wall fastener assembly with the insulation.