Channel anchor

Abstract

A channel anchor for embedding into masonry structures, the channel anchor having an anchor channel and a plurality of anchor shafts attached thereto, with the anchor shaft having a shaft-like structure with an elongated center shank having two ends, a head on one end and a base on the other end, and the anchor shaft being welded to the anchor channel by welding the base of the anchor shaft to the back of the anchor channel.

1 . A channel anchor comprising: 
 a) an anchor channel having a generally C-shaped channel having a back, two side and two ends, wherein the back does not have any receiving openings resulting in a generally uniform uninterrupted structure; and    b) at least one anchor shaft welded to the anchor channel, wherein the anchor shaft is a shaft-like structure having an elongated center shank having two ends, a head on one end and a base on the other end, and the anchor shaft is welded to the anchor channel by welding the base of the anchor shaft to the back of the anchor channel.    
   
   
       2 . The channel anchor as claimed in  claim 1 , wherein the center shank is an elongated shaft having a length measured axially between approximately 25 millimeters and 300 millimeters and a diameter of between 8 millimeters and 25 millimeters.  
   
   
       3 . The channel anchor as claimed in  claim 2 , wherein the center shank has a length of between approximately 50 millimeters and 150 millimeters and a diameter of between approximately 8 millimeters and 18 millimeters.  
   
   
       4 . The channel anchor as claimed in  claim 2 , wherein the center shank has a length of between approximately 50 millimeters and 100 millimeters and a diameter of between approximately 10 millimeters and 18 millimeters.  
   
   
       5 . The channel anchor as claimed in  claim 1 , wherein the head is an enlarged portion of the center shank having a diameter greater than that of the center shank and a length between approximately 3 millimeters and 25 millimeters.  
   
   
       6 . The channel anchor as claimed in  claim 5 , wherein the head has a length of between approximately 3 millimeters and 15 millimeters and a diameter of between 1.25 and 3 times the diameter of the center shank.  
   
   
       7 . The channel anchor as claimed in  claim 6 , wherein the head has a length of between approximately 3 millimeters and 8 millimeters and a diameter of approximately 2 times the diameter of the center shank.  
   
   
       8 . The channel anchor as claimed in  claim 2 , wherein the base is an enlarged portion of the center shank having a diameter greater than that of the center shank and a length between approximately 3 millimeters and 25 millimeters.  
   
   
       9 . The channel anchor as claimed in  claim 8 , wherein the base has a length of between approximately 3 millimeters and 15 millimeters and a diameter of between 1.25 and 3 times the diameter of the center shank.  
   
   
       10 . The channel anchor as claimed in  claim 9 , wherein the base has a length of between approximately 3 millimeters and 8 millimeters and a diameter of approximately 2 times the diameter of the center shank.  
   
   
       11 . The channel anchor as claimed in  claim 1 , wherein the back of the anchor channel is a continuous and substantially flat surface and the base comprises two opposing flat surfaces, a thickness, and a perimeter, one of the opposing flat surfaces of the base is attached to the center shank and the other of the opposing flat surfaces of the base is placed against the back of the anchor channel, and a weldment is made about the perimeter of the base thus welding the base to the back.  
   
   
       12 . The channel anchor as claimed in  claim 11 , wherein the anchor shaft is bonded perpendicular to the back of the anchor channel.  
   
   
       13 . The channel anchor as claimed in  claim 1 , wherein the anchor channel has a hollow interior defining a longitudinal slot.  
   
   
       14 . The channel anchor as claimed in  claim 13 , wherein the two ends form the longitudinal slot.  
   
   
       15 . The channel anchor as claimed in  claim 1 , wherein the anchor channel and the anchor shaft are made from the same material.  
   
   
       16 . The channel anchor as claimed in  claim 12 , wherein the anchor supports a force greater than 50 kN.  
   
   
       17 . The channel anchor as claimed in  claim 1 , wherein the cross sectional area of the base is greater than the cross sectional area of the shank.  
   
   
       18 . The channel anchor as claimed in  claim 1 , wherein the cross sectional area of the head is greater than the cross sectional area of the shank.  
   
   
       19 . A method for manufacturing a channel anchor comprising the steps of: 
 a) providing an anchor channel having a substantially flat back and side arms extending generally normal to the top and then turning inward towards each other so as to form a longitudinal slot opposite the back;    b) providing a plurality of anchor shafts each having a head, a center shank and a mounting base, wherein the base comprises two opposing flat surfaces, a thickness, and a perimeter;    c) placing and positioning the anchor shafts on the anchor channel such that the mounting base contacts the back of the anchor channel approximately mid-width, whereby one of the opposing flat surfaces of the base is attached to the center shank and the other of the opposing flat surfaces is placed against the back of the anchor channel; and    d) welding the mounting base to the back of the anchor channel such that a weldment is made about the perimeter of the base thus welding the base to the back,    wherein the anchor channel is not interrupted or deformed substantially during the welding process and once the weldment has cooled and cured, the channel anchor is a unitary structure.    
   
   
       20 . The method as claimed in  claim 19 , wherein the anchor channel has a continuous and substantially flat back and the anchor shaft is bonded to back.  
   
   
       21 . The method as claimed in  claim 20 , wherein the anchor channel remains continuous during the welding of the base to the anchor channel.  
   
   
       22 . An improved channel anchor comprising at least one anchor shaft and an anchor channel, the improvement comprising an anchor shaft having a shaft-like structure with an elongated center shank having two ends, a head on one end and a base on the other end, and the anchor shaft being welded to the anchor channel by welding the base of the anchor shaft to the back of the anchor channel, wherein the base comprises two opposing flat surfaces, a thickness, and a perimeter, and one of the opposing flat surfaces is attached to the center shank.  
   
   
       23 . The improved channel anchor as claimed in  claim 22 , wherein the center shank is an elongated shaft having a length measured axially between approximately 25 millimeters and 300 millimeters and a diameter of between 6 millimeters and 25 millimeters.  
   
   
       24 . The improved channel anchor as claimed in  claim 23 , wherein the head is an enlarged portion of the center shank having a diameter greater than that of the center shank and a length between approximately 3 millimeters and 25 millimeters.  
   
   
       25 . The improved channel anchor as claimed in  claim 24 , wherein the base is an enlarged portion of the center shank having a diameter greater than that of the center shank and a length between approximately 3 millimeters and 25 millimeters.