US20040055247A1 - High strength composite wall connectors having a tapered edge - Google Patents
High strength composite wall connectors having a tapered edge Download PDFInfo
- Publication number
- US20040055247A1 US20040055247A1 US10/254,168 US25416802A US2004055247A1 US 20040055247 A1 US20040055247 A1 US 20040055247A1 US 25416802 A US25416802 A US 25416802A US 2004055247 A1 US2004055247 A1 US 2004055247A1
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- sidewalls
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Images
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/38—Connections for building structures in general
- E04B1/41—Connecting devices specially adapted for embedding in concrete or masonry
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
- B28B19/003—Machines or methods for applying the material to surfaces to form a permanent layer thereon to insulating material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/005—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects with anchoring or fastening elements for the shaped articles
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
- E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
- E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
- E04C2/04—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres
- E04C2/044—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete
- E04C2002/045—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of concrete or other stone-like material; of asbestos cement; of cement and other mineral fibres of concrete with two parallel leaves connected by tie anchors
- E04C2002/046—Flat anchors
Definitions
- the present invention is in the field of composite wall structures and, more specifically, to the field of connectors used to secure together multiple layers of material within the composite wall structures.
- a commonly used measurement of the thermal insulating qualities of a material is the mathematical coefficient “R” which is a measure of the thermal resistance of a material.
- the coefficient R is typically equal to the inverse of the coefficient “K” which is a measure of the thermal conductivity of the material.
- K the coefficient of the coefficient
- a “high R value” material or device is therefore understood by those in the art as possessing a high thermal resistance or insulating ability.
- concrete which is formed from a mixture comprising a hydraulic cement binder, water and a relatively low cost and high compressive strength aggregate material, such as rocks, pebbles and sand. Together these form a relatively high strength, low cost building material.
- concrete has the drawback of offering poor insulation compared to highly insulating materials such as fiberglass or polymeric foam materials. While an 8 inch slab of concrete has an R value of 0.64, a 1 inch panel of polystyrene has an R value of 5.0. However, these latter materials, while highly insulative, also have the drawback of offering little or no structural strength or integrity.
- Composite action which is well known by those skilled in the art, generally describes how well a multi-layered panel, or composite wall, transfers shear forces between its different layers and is typically identified as a percentage between 0% and 100%.
- a layered panel having a very high composite action will transfer shear forces very well and will behave like a single laminated panel.
- a layered panel having a very low composite action will not transfer shear forces well and will behave more like a panel having a plurality of disconnected layers.
- Composite action can provide structural integrity to the wall. Accordingly, it is generally desirable to produce composite walls having high composite action so that they will remain intact when loads are applied to the wall.
- Existing connectors have thus far proven inadequate for providing composite walls with the desired composite action.
- composite walls generally include an insulation layer sandwiched between a structural layer and a fascia layer.
- the structural layer is typically used as the load-bearing member of the wall.
- the fascia layer is typically not used to bear a load separated from the structural layer because of insufficient composite action existing between the facia layer and the structural layer.
- the composite action of the wall was sufficiently high, e.g., between 60% to 100%, the fascia layer could potentially be used to bear a substantial portion of the overall load.
- the present invention is directed to improved connectors that are simple to manufacture and that can be used to provide high composite action to insulating composite walls.
- the connectors of the invention include a body having two substantially parallel sidewalls and a web portion extending therebetween.
- a cross-section of the body that includes the sidewalls and the web advantageously comprises the shape of an I, such that the web portion is advantageously generally perpendicular to the sidewalls.
- the body is generally divided into three segments, which are designated as the penetrating, mesial and trail segments, respectively.
- the penetrating segment includes a tapered end extending between the two parallel sidewalls and is configured for facilitating penetration of the connector through an insulating layer and into a first layer of a hardenable structural material such as concrete.
- the tapered end includes an edge that extends between, and which is generally perpendicular to, the two parallel sidewalls.
- the trailing segment of the body may be configured as desired so as to, e.g., facilitate gripping and/or to receive a driving force sufficient for driving the penetrating segment through the insulating layer.
- the mesial segment of the body simply extends between the first and second segments and is configured so as to penetrate into and reside within an insulation layer.
- the connectors of the invention may also include orienting means, nonmoveably affixed to the connector, for orienting the connector within the insulating layer at a predetermined depth.
- the orienting means may comprise at least one flange or other extension protruding laterally away from the body and located at or near the junction between the trailing segment and the mesial segment. The flange or other extension is configured to engage the insulating layer to inhibit the trailing segment from penetrating into the insulating layer during manufacture of the composite wall structure.
- the connectors of the invention also advantageously include anchoring means configured so as to anchor the connector within the hardened structural layers.
- anchoring means are provided within the penetration segment for anchoring the penetrating segment within a first layer of hardened structural material.
- Anchoring means are also advantageously provided within the trailing segment for anchoring the trailing segment within a second layer of hardened structural material.
- the anchoring means may include any structure or combination of structures that facilitate anchoring of the connectors within hardened structural materials, including but not limited to, holes, depressions, ridges, notches, recesses, flanges, extensions, and other irregularities in the body of the connector.
- the connectors of the invention are preferably formed from a highly insulative material, which results in highly insulative composite wall structures.
- the connectors can be formed from both thermoplastic or thermosetting plastic materials which has high strength resins.
- Preferred materials include polyphenylsulfones resins, polypthalamides, polyamides, polyarylsulfones, polycarbonates, polypthalamides, polysulfones, polyphthenyl sulfones, polyether sulfones and aliphatic polyketones.
- thermoset resins include polyester and vinyl esters.
- Other suitable thermoset materials include dialoyl phthalates, epoxy resins, furan resins and phenolic resins.
- copolymers and blends of the foregoing materials may be used.
- thermoplastics and thermosetting plastics provide the advantages of low cost, low weight and ease of manufacturing.
- an insulating layer is placed over a first layer of a hardenable structural material.
- the connectors of the invention are partially forced through the insulating layer so that at least a portion of the first segment of the connectors is inserted into the hardenable structural material.
- the tapered end on the connectors facilitates their insertion through the insulation and unhardened structural material.
- slots or holes can be formed into the insulation layer where the connectors are to be inserted.
- a flange or other stop at or near the interface between the mesial and trailing segments on the connectors orient the connectors at a predetermined depth within the insulation layer and keep the connector from passing completely through the insulation layer.
- a second layer of hardenable structural material is placed over the insulation layer, enveloping at least a portion of the second segment of the connectors.
- anchoring means on the connectors secure the connectors in place, respectively within the first and second layers, thereby holding the composite wall together.
- the connectors provide the assembled composite wall with about 50% to about 100% composite action, typically at least about 60% composite action, preferably at least about 70% composite action, more preferably at least about 80% composite action, and most preferably at least about 90% composite action.
- FIG. 1 illustrates a perspective view of one embodiment of the connector of the invention that includes a body having two parallel sidewalls, a web portion extending between the sidewalls, a first segment configured with a tapered end, a second segment configured with a non-tapered end, and a mesial segment extending between the first and second segments;
- FIG. 2 illustrates a cross-sectional perspective view of the connector of FIG. 1 that shows a cross-sectional area of the sidewalls and the web portion of the connector in the mesial segment along cross-sectional line 2 - 2 of FIG. 1;
- FIG. 3 illustrates a perspective view of one embodiment of the connector of the invention that includes a curved tapered end
- FIG. 4 illustrates a perspective view of one embodiment of the connector of the invention that includes anchoring means comprising recesses formed in the first and second segments of the connector;
- FIG. 5 illustrates a perspective view of one embodiment of the connector of the invention that includes sidewalls that terminate into chisel-like ends that are perpendicular to the main tapered end;
- FIG. 6 illustrates a front elevational cross-section view of a partially completed composite wall structure
- FIG. 7 illustrates a front elevational cross-section view of a composite wall structure.
- the embodiments of the present invention are generally directed to improved connectors used for the manufacture of insulating composite walls that include an insulation layer sandwiched between two layers of hardenable structural material.
- the connectors are specifically configured to secure the two layers of structural material against the insulation layer and to provide the resultant composite wall with from about 50% to 100% composite action.
- composite action generally refers to ability of the composite wall to act like a single laminated wall rather than like a wall having a plurality of disconnected layers.
- PCI PreCast/Prestressed Concrete Institute
- hardenable structural material refers to a material that is configured to change from an unhardened state, in which the material is generally characterized as uncured, deformable, or fluid, to a hardened state, in which the material is generally characterized as cured, or solid.
- a hardenable structural material includes concrete material including a hydraulic cement binder, water, an aggregate material and other appropriate admixtures. Plasters, mortars, plastics, and resins may also comprise hardenable structural material.
- hardenable structural material is sometimes used herein interchangeably with the term “structural material.”
- insulation composite wall generally refers to a wall or layered structure that includes an insulation layer disposed between two layers of hardenable structural material. Although the insulating composite wall generally consists of only three layers, each of these layers may also include a plurality of layers.
- tapered end refers to a portion of the connector having a progressively smaller thickness toward an end thereof.
- the tapered end may be sharp or blunt as desired.
- the connectors of the invention are preferably injection molded from any appropriate resin or other high strength plastic material, although they may also be molded by resin transfer molding, reaction injection molding, or any other single step or relatively simple molding process known in the art. It is also within the scope of the invention to utilize multi-step manufacturing processes, such as those that employ assembly and/or machining steps.
- a preferred resinous material is polycarbonate resin because of the ease in which it may be injection molded.
- Other similar resinous materials include polyphthalamide (PPA) and polycarbonate-polybutylene terephthalate alloy, which are generally less expensive than polycarbonate resins.
- PPA polyphthalamide
- Other resins that may be used to manufacture the connectors of the invention include, but are not limited to, epoxy resins, thermoset plastics, and other high strength, high R-value materials may be used. The high R value generally minimizes the transfer of heat between the two layers of the structural material in the composite wall that occurs through the connectors.
- FIG. 1 illustrates a perspective view of one embodiment of the connector of the invention.
- the connector 10 includes a body 12 having two sidewalls 14 and a web portion 16 that extends between the sidewalls 14 .
- the body 12 of the connector 10 is generally divided into three segments, including a penetrating segment 20 , a trailing segment 22 , and a mesial segment 24 .
- the penetrating segment 20 includes a tapered end 26 that extends between the two sidewalls 14 .
- the sidewalls 14 are parallel and the tapered end 26 comprises a straight edge 27 perpendicularly extending between the sidewalls 14 .
- the tapered end 26 is specifically configured for being inserted through an insulation layer and into a layer of hardenable structural material during the manufacture of a corresponding composite wall, as described in more detail below in reference to FIG. 6.
- the tapered end 26 of the connector 10 is shown to comprise a straight edge 27 , it will be appreciated that, according to other embodiments, the tapered end 26 may comprise other shapes.
- the tapered end may be curved convexly, curved concavely, pointed convexly, pointed concavely, etc., to further facilitate the insertion of the connector through the insulation layer of the composite wall.
- the edge 27 may be sharp or blunt as desired.
- FIG. 3 illustrates an embodiment in which a tapered end 26 ′ is curved convexly so as to have a convex edge 27 ′.
- FIG. 5 illustrates an embodiment in which the tapered end 26 ′′ is curved concavely so as to have a concave edge 27 ′′.
- FIG. 2 illustrates a cross-sectional area of the connector 10 taken along line 2 - 2 of FIG. 1.
- the cross-section of the sidewalls 14 and the web portion 16 taken through the mesial segment 24 of the body 12 generally comprises the shape of an I. It will be appreciated that this shape generally provides the connector with a high moment of inertia that is conducive to providing a high composite action.
- the distance between the sidewalls 14 corresponding with the width of the web portion 16 , is within the range of about 2 inches and about 3 inches.
- the width of the sidewalls 14 is preferably within the range of about 1 ⁇ 8 to about 1 ⁇ 2 of an inch.
- the width of the sidewalls 14 is typically at least 50% greater than the thickness of the web portion 16 , preferably at least twice the thickness of the web portion 16 , more preferably at least three times the thickness of the web portion 16 .
- the sidewalls 14 are shown to be generally rectilinear, it will be appreciated that the sidewalls 14 may also comprise other shapes. For instance, the sidewalls may be square, oval, circular, triangular, hexagonal, etc., while still providing the connector 10 with a high moment of inertia. It will also be appreciated that although the web portion 16 is shown to extend substantially planarly and perpendicularly between the sidewalls 14 , the web portion 16 may also be configured according to alternative embodiments to extend between the sidewalls 14 along an irregular or curved trajectory.
- the sidewalls 14 generally terminate within the first segment 20 into corresponding angles faces 30 that are disposed on opposing ends of the tapered end 26 .
- This angled configuration is particularly suitable for facilitating the insertion of the connector 10 through the insulation layer of a composite wall.
- the sidewalls 14 may also terminate in the tapered end 26 with different configurations. For instance, according to the embodiment shown in FIG. 5, the sidewalls 14 terminate into chisel-like edges 32 disposed on opposing ends of the tapered end 26 ′′. This embodiment may be useful for increasing the structural stability to the connector 10 near the tapered end 26 ′′, while still facilitating insertion of the connection 10 within an insulation layer.
- the sidewalls 14 may be configured to gradually taper from the second segment 22 to the tapered edge rather than tapering only in the first segment 22 as shown.
- the connectors 10 of the invention may include a trailing wall 40 that extends at least partially between the sidewalls 14 within the trailing segment 22 .
- the wall 40 may comprise any desired shape according to the invention.
- One use of the wall is for gripping the connector 10 .
- the wall 40 can also be used for receiving a driving force sufficient for driving the connector 10 through the insulating layer of a composite wall, as described below in more detail.
- Yet another function of the wall 40 is to provide an anchoring means for anchoring the second segment within a layer of structural material.
- the protrusion of the wall 40 may be used as an anchoring means for anchoring the connector 10 within a layer of structural material during the manufacture of a composite wall, as described below.
- the connectors 10 of the invention comprise anchoring means for anchoring the connectors 10 within the layers of the composite wall.
- Anchoring means may comprise any suitable recess, hole, ridge, protrusion, depression, flange, wall, extension, irregularity, or other formation that can be used to anchor the connector 10 into the structural material of a composite wall.
- structural material flows into or around the anchoring means where it subsequently hardens. Once hardened, the structural material securely engages the anchoring means, thereby securing the connector in a desired placement within the layers of the structural material.
- the recess 42 defined by the boundaries of the sidewalls 14 , the trailing wall 40 , and the flange 44 may comprise suitable anchoring means within the trailing segment 22 .
- structural material flows into and hardens within the recess 42 during the manufacture of the composite wall, thereby anchoring the connector 10 within a desired placement.
- Hole formations 46 shown in FIGS. 1 - 3 and 5 - 7 comprise at least a portion of the anchoring means in both the penetrating and trailing segments.
- anchoring means may also include recesses 48 , such as those illustrated in the first penetrating segment 20 , or large recesses 50 formed in the trailing segment 22 .
- the large recesses 50 formed in the second segment 22 are generally defined by the boundaries of the sidewalls 14 , the trailing wall 40 , the flange 44 , and a divider 52 .
- the connectors of the invention also include orienting means for orienting the connectors within the insulating layer of a composite wall and at a predetermined depth.
- the orienting means may include a flange 44 nonmoveably affixed to and protruding away from the web portion 16 between the second segment 22 and the mesial segment 24 .
- the flange 44 is specifically configured to engage the insulating layer of a composite wall to prevent the second segment 22 from passing through the insulating layer.
- the flange 44 may extend partially or wholly between sidewalls 14 .
- a first layer 60 of a structural material is poured into an appropriate form (not shown).
- the first structural layer will be a rectangular slab, although it may also include other design, ornamental or structural features. The only limitation is that it have a thickness or depth great enough to give the first structural layer 60 adequate strength and the ability to firmly anchor the penetrating segment 20 of the connector 10 therein.
- an insulating layer 70 is placed adjacent to the exposed side of the first structural layer 60 .
- the insulating layer 70 may, although not necessarily, include a plurality of holes or slots through which the connectors of the invention will be inserted.
- the connector 10 is then pushed or driven through the insulation layer 70 and into the first structural layer 60 while the structural material is still unhardened.
- the tapered end 26 on the connector 10 is configured to facilitate passage of the connector 10 through any preformed holes or to cut through the insulation when there are not any preformed holes in the insulation layer, thereby facilitating the insertion of the connector 10 in either event.
- a driving force may be applied by hand or with a tool, such as a hammer or mallet.
- the connector 10 is inserted to the insulation layer 70 until the flange 44 protruding away from the web portion 16 engages against the insulation layer 70 , thereby indicating the desired depth has been reached.
- the flange 44 comprises one suitable means for orienting the connector 10 within the insulation layer 70 at a predetermined depth.
- the structural material of the first structural layer 60 flows into and engages hole formations 46 or other anchoring means of the first segment 20 of the connector 10 . Vibration of the first layer and/or movement of the connector 10 may be necessary to ensure adequate engagement of the penetrating segment 20 with the structural material. Once the structural material cures then the connector 10 is effectively anchored within the first structural layer 60 .
- a second layer of structural material is poured over the surface of the insulating layer 70 to form the second structural layer 80 , as shown in FIG. 7.
- the depth of the second structural layer 80 should be such that is completely, or at least substantially, engulfs the head 40 of the connector and engages any anchoring means formed in the second segment 22 of the connector 10 , thereby providing an adequate anchoring effect of the connector 10 within the second structural layer 22 .
- the flange 44 also aids in preventing the hardened second structural layer 80 from collapsing against the first structural layer 60 when hardened and tilted up or otherwise positioned for use.
- a second insulating layer over the yet unhardened second structural layer 80 , followed by the insertion of additional connector rods through the second insulation layer and second structural layer. Thereafter, a third structural layer will be cast over the surface of the second insulating layer as before. Because of the simplicity of molding the connectors of the present invention, an adapted connector could be molded that would connect three or more structural layers together. Or the three or more structural layers can be held together using overlapping connectors of the type shown in FIGS. 1 - 7 .
- the connectors of the invention are capable of providing an assembled composite wall with about 50% to about 100% composite action. It will be appreciated that this is a significant improvement over prior art connectors that have been found, according to independent testing, to provide only 10% composite action.
- One benefit of providing such superior composite action is that is enables loads to be independently carried by each of the structural layers. It will be appreciated that this is not possible when the composite action is small, such as when using the connectors of the prior art, because the shear forces caused by the independent loads could cause the structural layers to break away from the composite wall.
- the connectors according to the invention typically provide at least about 60% composite action, preferably at least about 70% composite action, more preferably at least about 80% composite action, and most preferably at least about 90% composite action.
Abstract
Connectors configured for providing composite wall structures with high composite action. The connectors comprise a body having two sidewalls and a web portion extending therebetween. The body also includes a tapered end at one side for facilitating penetration of the connector through layers of the composite wall during manufacture. Orienting means orient the connector at a predetermined depth within the layers of the composite wall during manufacture. Anchoring means anchor the connectors of the invention to layers of structural material placed on opposing sides of an insulation layer of the composite wall.
Description
- 1. The Field of the Invention
- The present invention is in the field of composite wall structures and, more specifically, to the field of connectors used to secure together multiple layers of material within the composite wall structures.
- 2. The Relevant Technology
- As new materials and compositions have been continuously developed, novel methods of synergistically combining apparently unrelated materials to form useful composites have also been developed. This is true of the area of building and construction in which high strength structural walls have been fabricated and then coated or layered with highly insulative materials having relatively low strength to provide a structure of both high strength and high insulation. In general, insulation is attached to the structural component. The outer wall structure is first erected. Then, an insulating material is placed on the inside of the outer wall structure, and an inner wall is placed over the insulating material to protect and hide it. The purpose of the insulation layer is to prevent, or at least slow, the transfer of thermal energy between the inner and outer walls.
- A commonly used measurement of the thermal insulating qualities of a material is the mathematical coefficient “R” which is a measure of the thermal resistance of a material. The coefficient R is typically equal to the inverse of the coefficient “K” which is a measure of the thermal conductivity of the material. A “high R value” material or device is therefore understood by those in the art as possessing a high thermal resistance or insulating ability.
- One of the least expensive and strongest building materials that has found extensive use in the construction industry is concrete, which is formed from a mixture comprising a hydraulic cement binder, water and a relatively low cost and high compressive strength aggregate material, such as rocks, pebbles and sand. Together these form a relatively high strength, low cost building material. Unfortunately, concrete has the drawback of offering poor insulation compared to highly insulating materials such as fiberglass or polymeric foam materials. While an 8 inch slab of concrete has an R value of 0.64, a 1 inch panel of polystyrene has an R value of 5.0. However, these latter materials, while highly insulative, also have the drawback of offering little or no structural strength or integrity.
- Although structural walls made of cement or masonry can be fitted and even retrofitted with any number of insulating materials, including insulating mats or foams that are sprayed between an inner and outer wall, the insulation material is not able to impart the most efficient insulation possible due to the required structural briding of the outer structural wall with the inner structural wall. Such structural bridging is necessary in order for the two-wall structure to have high strength and integrity and to prevent the two walls from collapsing together or separating apart during construction and subsequent use of the building. This has been accomplished through the use of metal studs, bolts, or beams. However, because metal is a very good conductive material (and therefore has very low insulation), such studs, bolts, beams, or other means for structurally bridging the two walls together also create a conductive thermal bridge across which heat can readily flow, notwithstanding their being surrounded by ample amounts of insulating material. As a result, heat can rapidly flow from a relatively warm inside wall to a colder outside wall during cold weather, for example. Therefore, although an insulating material may have a relatively high R value, the net R value of the composite wall structure can often be far less due to thermal bridging, thus negating or minimizing the effect of adding additional layers of insulation. Examples of U.S. Patents that disclose a composite wall structure held together using metal tie rods or studs include the following: U.S. Pat. No. 4,393,635 to Long, U.S. Pat. No. 4,329,821 to Long et al., U.S. Pat. No. 2,775,018 to McLaughlin, U.S. Pat. No. 2,645,929 to Jones, and U.S. Pat. No. 2,412,744 to Nelson.
- In order to substantially overcome the problems of thermal bridging, some have employed the use of tie rods having a metal portion passing through the concrete layers and a thermally insulating portion passing through the insulating layer (e.g., U.S. Pat. No. 4,545,163 to Asselin). Yet others have developed highly insulative connector rods that are made entirely from high R-value materials in order to connect together the two concrete structural layers while minimizing the thermal bridging effect between the outer concrete layers. For example, U.S. Pat. No. 4,829,733 to Long (hereinafter the “Long '733 Patent)) discloses a plastic connector for forming an insulated wall having inner and outer concrete structural layers with highly insulating layers sandwiched therebetween. Although the plastic connector described in the Long '733 Patent has found some use in the construction industry, the connector described therein can be relatively expensive and difficult to manufacture due to the materials and processes required for forming the connector.
- Another problem with the aforementioned connectors is that they do not provide adequate composite action. Composite action, which is well known by those skilled in the art, generally describes how well a multi-layered panel, or composite wall, transfers shear forces between its different layers and is typically identified as a percentage between 0% and 100%. A layered panel having a very high composite action will transfer shear forces very well and will behave like a single laminated panel. Whereas, a layered panel having a very low composite action will not transfer shear forces well and will behave more like a panel having a plurality of disconnected layers. Composite action can provide structural integrity to the wall. Accordingly, it is generally desirable to produce composite walls having high composite action so that they will remain intact when loads are applied to the wall. Existing connectors, however, have thus far proven inadequate for providing composite walls with the desired composite action.
- Although Composite Technologies Corporation, the assignee of the Long '733 Patent, has made the claim that some of its connectors are able to provide 40% to 60% composite action, independent testing has shown that such connectors only provide about 10% composite action.
- As generally described above, composite walls generally include an insulation layer sandwiched between a structural layer and a fascia layer. The structural layer is typically used as the load-bearing member of the wall. The fascia layer is typically not used to bear a load separated from the structural layer because of insufficient composite action existing between the facia layer and the structural layer. However, if the composite action of the wall was sufficiently high, e.g., between 60% to 100%, the fascia layer could potentially be used to bear a substantial portion of the overall load.
- Accordingly, there is currently a need in the art for improved connectors that are simple to manufacture and that can be used to provide insulating composite walls with high composite action.
- The present invention is directed to improved connectors that are simple to manufacture and that can be used to provide high composite action to insulating composite walls.
- According to one embodiment, the connectors of the invention include a body having two substantially parallel sidewalls and a web portion extending therebetween. A cross-section of the body that includes the sidewalls and the web advantageously comprises the shape of an I, such that the web portion is advantageously generally perpendicular to the sidewalls. The body is generally divided into three segments, which are designated as the penetrating, mesial and trail segments, respectively. The penetrating segment includes a tapered end extending between the two parallel sidewalls and is configured for facilitating penetration of the connector through an insulating layer and into a first layer of a hardenable structural material such as concrete. According to one embodiment, the tapered end includes an edge that extends between, and which is generally perpendicular to, the two parallel sidewalls.
- The trailing segment of the body may be configured as desired so as to, e.g., facilitate gripping and/or to receive a driving force sufficient for driving the penetrating segment through the insulating layer. The mesial segment of the body simply extends between the first and second segments and is configured so as to penetrate into and reside within an insulation layer.
- The connectors of the invention may also include orienting means, nonmoveably affixed to the connector, for orienting the connector within the insulating layer at a predetermined depth. According to one embodiment, the orienting means may comprise at least one flange or other extension protruding laterally away from the body and located at or near the junction between the trailing segment and the mesial segment. The flange or other extension is configured to engage the insulating layer to inhibit the trailing segment from penetrating into the insulating layer during manufacture of the composite wall structure.
- The connectors of the invention also advantageously include anchoring means configured so as to anchor the connector within the hardened structural layers. According to one embodiment, anchoring means are provided within the penetration segment for anchoring the penetrating segment within a first layer of hardened structural material. Anchoring means are also advantageously provided within the trailing segment for anchoring the trailing segment within a second layer of hardened structural material. The anchoring means may include any structure or combination of structures that facilitate anchoring of the connectors within hardened structural materials, including but not limited to, holes, depressions, ridges, notches, recesses, flanges, extensions, and other irregularities in the body of the connector.
- The connectors of the invention are preferably formed from a highly insulative material, which results in highly insulative composite wall structures. For example, the connectors can be formed from both thermoplastic or thermosetting plastic materials which has high strength resins. Preferred materials include polyphenylsulfones resins, polypthalamides, polyamides, polyarylsulfones, polycarbonates, polypthalamides, polysulfones, polyphthenyl sulfones, polyether sulfones and aliphatic polyketones. Less preferred materials that are nevertheless adequate for many applications include acrylics, polyethylene, polypropylene, acrylonitrile-butadiene-styrene copolymers, polyfluorocarbons, polybutadienes, polybutylene terapthalates, polyesters, polyethylene terephthalates, polyphthenelyne ethers, polyphthenelyne oxides, polyphthenyline sulfides, polyphthalate carbonates, polypropylenes, polystyrenes, polyurethanes, polyvinyl chlorites, and polyxylenes. Preferred thermoset resins include polyester and vinyl esters. Other suitable thermoset materials include dialoyl phthalates, epoxy resins, furan resins and phenolic resins. In addition, copolymers and blends of the foregoing materials may be used.
- The criteria used to select an appropriate material include concerns for strength, flexibility, insulation ability, cost and moldability. In general, thermoplastics and thermosetting plastics provide the advantages of low cost, low weight and ease of manufacturing.
- During manufacture of an insulating composite wall, an insulating layer is placed over a first layer of a hardenable structural material. The connectors of the invention are partially forced through the insulating layer so that at least a portion of the first segment of the connectors is inserted into the hardenable structural material. The tapered end on the connectors facilitates their insertion through the insulation and unhardened structural material. To further facilitate insertion of the connectors, slots or holes can be formed into the insulation layer where the connectors are to be inserted. A flange or other stop at or near the interface between the mesial and trailing segments on the connectors orient the connectors at a predetermined depth within the insulation layer and keep the connector from passing completely through the insulation layer. A second layer of hardenable structural material is placed over the insulation layer, enveloping at least a portion of the second segment of the connectors. Once the hardenable structural material hardens, anchoring means on the connectors secure the connectors in place, respectively within the first and second layers, thereby holding the composite wall together. The connectors provide the assembled composite wall with about 50% to about 100% composite action, typically at least about 60% composite action, preferably at least about 70% composite action, more preferably at least about 80% composite action, and most preferably at least about 90% composite action.
- These and other benefits, advantages and features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
- In order that the manner in which the above recited and other benefits, advantages and features of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
- FIG. 1 illustrates a perspective view of one embodiment of the connector of the invention that includes a body having two parallel sidewalls, a web portion extending between the sidewalls, a first segment configured with a tapered end, a second segment configured with a non-tapered end, and a mesial segment extending between the first and second segments;
- FIG. 2 illustrates a cross-sectional perspective view of the connector of FIG. 1 that shows a cross-sectional area of the sidewalls and the web portion of the connector in the mesial segment along cross-sectional line2-2 of FIG. 1;
- FIG. 3 illustrates a perspective view of one embodiment of the connector of the invention that includes a curved tapered end;
- FIG. 4 illustrates a perspective view of one embodiment of the connector of the invention that includes anchoring means comprising recesses formed in the first and second segments of the connector;
- FIG. 5 illustrates a perspective view of one embodiment of the connector of the invention that includes sidewalls that terminate into chisel-like ends that are perpendicular to the main tapered end;
- FIG. 6 illustrates a front elevational cross-section view of a partially completed composite wall structure; and
- FIG. 7 illustrates a front elevational cross-section view of a composite wall structure.
- A detailed description of the connectors of the invention will now be provided with specific reference to figures illustrating various embodiments of the invention. It will be appreciated that like structures will be provided with like reference designations.
- The embodiments of the present invention are generally directed to improved connectors used for the manufacture of insulating composite walls that include an insulation layer sandwiched between two layers of hardenable structural material. The connectors are specifically configured to secure the two layers of structural material against the insulation layer and to provide the resultant composite wall with from about 50% to 100% composite action.
- The term “composite action,” which is well known in the art, generally refers to ability of the composite wall to act like a single laminated wall rather than like a wall having a plurality of disconnected layers. The following equation is used by the concrete industry (PreCast/Prestressed Concrete Institute (PCI)) to define composite action as a percentage, within a range of 0% to 100%: k=(Iexp−Inc)/(Ic−Inc), wherein Iexp is the experimentally determined moment of inertia of the test wall and Inc and Ic are the respective theoretical values of the moments of inertia of the fully composite wall and of the noncomposite wall.
- The term “hardenable structural material” refers to a material that is configured to change from an unhardened state, in which the material is generally characterized as uncured, deformable, or fluid, to a hardened state, in which the material is generally characterized as cured, or solid. One nonlimiting example of a hardenable structural material includes concrete material including a hydraulic cement binder, water, an aggregate material and other appropriate admixtures. Plasters, mortars, plastics, and resins may also comprise hardenable structural material. The term “hardenable structural material” is sometimes used herein interchangeably with the term “structural material.”
- The term “insulating composite wall,” as used herein, generally refers to a wall or layered structure that includes an insulation layer disposed between two layers of hardenable structural material. Although the insulating composite wall generally consists of only three layers, each of these layers may also include a plurality of layers.
- The term “tapered end” as used herein, refers to a portion of the connector having a progressively smaller thickness toward an end thereof. The tapered end may be sharp or blunt as desired.
- The connectors of the invention are preferably injection molded from any appropriate resin or other high strength plastic material, although they may also be molded by resin transfer molding, reaction injection molding, or any other single step or relatively simple molding process known in the art. It is also within the scope of the invention to utilize multi-step manufacturing processes, such as those that employ assembly and/or machining steps.
- A preferred resinous material is polycarbonate resin because of the ease in which it may be injection molded. Other similar resinous materials include polyphthalamide (PPA) and polycarbonate-polybutylene terephthalate alloy, which are generally less expensive than polycarbonate resins. Other resins that may be used to manufacture the connectors of the invention include, but are not limited to, epoxy resins, thermoset plastics, and other high strength, high R-value materials may be used. The high R value generally minimizes the transfer of heat between the two layers of the structural material in the composite wall that occurs through the connectors.
- Although not necessary in many instances, it may be desirable to incorporate within the resinous material or other plastic material fibers such as glass fibers, carbon fibers, boron fibers, ceramic fibers, and the like in order to increase the tensile strength, bending strength, shear strength and toughness of the connectors.
- Attention is now directed to FIG. 1, which illustrates a perspective view of one embodiment of the connector of the invention. As shown, the
connector 10 includes abody 12 having twosidewalls 14 and aweb portion 16 that extends between the sidewalls 14. Thebody 12 of theconnector 10 is generally divided into three segments, including a penetratingsegment 20, a trailingsegment 22, and amesial segment 24. - As shown, the penetrating
segment 20 includes atapered end 26 that extends between the twosidewalls 14. According to one embodiment, thesidewalls 14 are parallel and thetapered end 26 comprises astraight edge 27 perpendicularly extending between the sidewalls 14. Thetapered end 26 is specifically configured for being inserted through an insulation layer and into a layer of hardenable structural material during the manufacture of a corresponding composite wall, as described in more detail below in reference to FIG. 6. Although thetapered end 26 of theconnector 10 is shown to comprise astraight edge 27, it will be appreciated that, according to other embodiments, thetapered end 26 may comprise other shapes. For instance, the tapered end may be curved convexly, curved concavely, pointed convexly, pointed concavely, etc., to further facilitate the insertion of the connector through the insulation layer of the composite wall. Theedge 27 may be sharp or blunt as desired. FIG. 3 illustrates an embodiment in which atapered end 26′ is curved convexly so as to have aconvex edge 27′. FIG. 5 illustrates an embodiment in which thetapered end 26″ is curved concavely so as to have aconcave edge 27″. - FIG. 2 illustrates a cross-sectional area of the
connector 10 taken along line 2-2 of FIG. 1. As shown in FIG. 2, the cross-section of thesidewalls 14 and theweb portion 16 taken through themesial segment 24 of thebody 12 generally comprises the shape of an I. It will be appreciated that this shape generally provides the connector with a high moment of inertia that is conducive to providing a high composite action. According to one preferred embodiment, the distance between the sidewalls 14, corresponding with the width of theweb portion 16, is within the range of about 2 inches and about 3 inches. The width of thesidewalls 14 is preferably within the range of about ⅛ to about ½ of an inch. The width of thesidewalls 14 is typically at least 50% greater than the thickness of theweb portion 16, preferably at least twice the thickness of theweb portion 16, more preferably at least three times the thickness of theweb portion 16. - Although the
sidewalls 14 are shown to be generally rectilinear, it will be appreciated that thesidewalls 14 may also comprise other shapes. For instance, the sidewalls may be square, oval, circular, triangular, hexagonal, etc., while still providing theconnector 10 with a high moment of inertia. It will also be appreciated that although theweb portion 16 is shown to extend substantially planarly and perpendicularly between the sidewalls 14, theweb portion 16 may also be configured according to alternative embodiments to extend between the sidewalls 14 along an irregular or curved trajectory. - As shown in FIG. 1, the
sidewalls 14 generally terminate within thefirst segment 20 into corresponding angles faces 30 that are disposed on opposing ends of thetapered end 26. This angled configuration is particularly suitable for facilitating the insertion of theconnector 10 through the insulation layer of a composite wall. It will be appreciated, however, that thesidewalls 14 may also terminate in thetapered end 26 with different configurations. For instance, according to the embodiment shown in FIG. 5, thesidewalls 14 terminate into chisel-like edges 32 disposed on opposing ends of thetapered end 26″. This embodiment may be useful for increasing the structural stability to theconnector 10 near thetapered end 26″, while still facilitating insertion of theconnection 10 within an insulation layer. According to another embodiment, thesidewalls 14 may be configured to gradually taper from thesecond segment 22 to the tapered edge rather than tapering only in thefirst segment 22 as shown. - Returning now to FIG. 1, it is shown how the
connectors 10 of the invention may include a trailingwall 40 that extends at least partially between the sidewalls 14 within the trailingsegment 22. It will be appreciated that thewall 40 may comprise any desired shape according to the invention. One use of the wall is for gripping theconnector 10. Thewall 40 can also be used for receiving a driving force sufficient for driving theconnector 10 through the insulating layer of a composite wall, as described below in more detail. Yet another function of thewall 40 is to provide an anchoring means for anchoring the second segment within a layer of structural material. For instance, the protrusion of thewall 40 may be used as an anchoring means for anchoring theconnector 10 within a layer of structural material during the manufacture of a composite wall, as described below. - According to one preferred embodiment, the
connectors 10 of the invention comprise anchoring means for anchoring theconnectors 10 within the layers of the composite wall. Anchoring means may comprise any suitable recess, hole, ridge, protrusion, depression, flange, wall, extension, irregularity, or other formation that can be used to anchor theconnector 10 into the structural material of a composite wall. During the manufacture of a composite wall, structural material flows into or around the anchoring means where it subsequently hardens. Once hardened, the structural material securely engages the anchoring means, thereby securing the connector in a desired placement within the layers of the structural material. - As shown in FIGS.1-3, the
recess 42 defined by the boundaries of thesidewalls 14, the trailingwall 40, and theflange 44 may comprise suitable anchoring means within the trailingsegment 22. In particular, structural material flows into and hardens within therecess 42 during the manufacture of the composite wall, thereby anchoring theconnector 10 within a desired placement.Hole formations 46, shown in FIGS. 1-3 and 5-7 comprise at least a portion of the anchoring means in both the penetrating and trailing segments. - As shown in FIG. 4, anchoring means may also include
recesses 48, such as those illustrated in the first penetratingsegment 20, orlarge recesses 50 formed in the trailingsegment 22. The large recesses 50 formed in thesecond segment 22 are generally defined by the boundaries of thesidewalls 14, the trailingwall 40, theflange 44, and adivider 52. - According to one embodiment, the connectors of the invention also include orienting means for orienting the connectors within the insulating layer of a composite wall and at a predetermined depth. According to the embodiments shown in FIGS.1-7, the orienting means may include a
flange 44 nonmoveably affixed to and protruding away from theweb portion 16 between thesecond segment 22 and themesial segment 24. Theflange 44 is specifically configured to engage the insulating layer of a composite wall to prevent thesecond segment 22 from passing through the insulating layer. Theflange 44 may extend partially or wholly betweensidewalls 14. - Turning now to FIGS. 6 and 7, it is shown how the connectors of the invention can be sued to manufacture a composite wall. In a preferred method for manufacturing composite wall structures, a
first layer 60 of a structural material is poured into an appropriate form (not shown). In general, the first structural layer will be a rectangular slab, although it may also include other design, ornamental or structural features. The only limitation is that it have a thickness or depth great enough to give the firststructural layer 60 adequate strength and the ability to firmly anchor the penetratingsegment 20 of theconnector 10 therein. - Before the first
structural layer 60 obtains such rigidity that aconnector 10 cannot be inserted therein without damaging the ultimate structural integrity and strength of the firststructural layer 60, an insulatinglayer 70 is placed adjacent to the exposed side of the firststructural layer 60. The insulatinglayer 70 may, although not necessarily, include a plurality of holes or slots through which the connectors of the invention will be inserted. - The
connector 10 is then pushed or driven through theinsulation layer 70 and into the firststructural layer 60 while the structural material is still unhardened. Thetapered end 26 on theconnector 10 is configured to facilitate passage of theconnector 10 through any preformed holes or to cut through the insulation when there are not any preformed holes in the insulation layer, thereby facilitating the insertion of theconnector 10 in either event. In order to insert theconnector 10 to a desired depth, it may be necessary to apply a driving force to thewall 40 of theconnector 10. This driving force may be applied by hand or with a tool, such as a hammer or mallet. Theconnector 10 is inserted to theinsulation layer 70 until theflange 44 protruding away from theweb portion 16 engages against theinsulation layer 70, thereby indicating the desired depth has been reached. Accordingly, theflange 44 comprises one suitable means for orienting theconnector 10 within theinsulation layer 70 at a predetermined depth. - Once the
connector 10 is properly oriented within theinsulation layer 70, the structural material of the firststructural layer 60 flows into and engageshole formations 46 or other anchoring means of thefirst segment 20 of theconnector 10. Vibration of the first layer and/or movement of theconnector 10 may be necessary to ensure adequate engagement of the penetratingsegment 20 with the structural material. Once the structural material cures then theconnector 10 is effectively anchored within the firststructural layer 60. - After the first
structural layer 60 has achieved an adequate level of hardness or strength, a second layer of structural material is poured over the surface of the insulatinglayer 70 to form the second structural layer 80, as shown in FIG. 7. The depth of the second structural layer 80 should be such that is completely, or at least substantially, engulfs thehead 40 of the connector and engages any anchoring means formed in thesecond segment 22 of theconnector 10, thereby providing an adequate anchoring effect of theconnector 10 within the secondstructural layer 22. Theflange 44 also aids in preventing the hardened second structural layer 80 from collapsing against the firststructural layer 60 when hardened and tilted up or otherwise positioned for use. - In some cases it may be desirable to lay a second insulating layer over the yet unhardened second structural layer80, followed by the insertion of additional connector rods through the second insulation layer and second structural layer. Thereafter, a third structural layer will be cast over the surface of the second insulating layer as before. Because of the simplicity of molding the connectors of the present invention, an adapted connector could be molded that would connect three or more structural layers together. Or the three or more structural layers can be held together using overlapping connectors of the type shown in FIGS. 1-7.
- It has been found that the connectors of the invention are capable of providing an assembled composite wall with about 50% to about 100% composite action. It will be appreciated that this is a significant improvement over prior art connectors that have been found, according to independent testing, to provide only 10% composite action. One benefit of providing such superior composite action is that is enables loads to be independently carried by each of the structural layers. It will be appreciated that this is not possible when the composite action is small, such as when using the connectors of the prior art, because the shear forces caused by the independent loads could cause the structural layers to break away from the composite wall.
- The connectors according to the invention typically provide at least about 60% composite action, preferably at least about 70% composite action, more preferably at least about 80% composite action, and most preferably at least about 90% composite action.
- Although specific embodiments of the invention have been illustrated and described herein, it will be appreciated that the present claimed invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative, not restrictive. The scope of the invention, is, therefore, indicated by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.
Claims (30)
1. A connector for use in making an insulating composite wall structure, the connector comprising a body having a penetrating segment configured to reside within a first structural layer, a trailing segment configured to reside within a second structural layer, and a mesial segment between the penetration and trailing segments configured to reside within an insulating layer when the connector is in use, the body comprising:
two sidewalls;
a web portion extending between the two sidewalls;
a tapered end configured to facilitate penetration of the connector through an insulating layer and a layer of unhardened structural material adjacent to the insulating layer;
orienting means for limiting penetration of the connector through an insulating layer at a predetermined depth; and
anchoring means for anchoring at least one of the penetrating and trailing segments within a corresponding layer of hardened structural material.
2. A connection as recited in claim 1 , the sidewalls and the web portion having a substantially I-shaped cross section within the mesial segment.
3. A connector is recited in claim 1 , the sidewalls being substantially parallel and the web portion being substantially perpendicular to the sidewalls.
4. A connector is recited in claim 1 , the sidewalls having a width that is at least 50% greater than the thickness of the web portion.
5. A connector is recited in claim 1 , the sidewalls having a width that is at least twice the thickness of the web portion.
6. A connector is recited in claim 1 , the sidewalls having a width that is at least three times the thickness of the web portion.
7. A connector as recited in claim 1 , the orienting means comprising at least one protrusion extending away from the web portion at or near where the mesial and trailing segments intersect.
8. A connector as recited in claim 1 , the body comprising at least one of a cured resinous material or a thermoplastic material.
9. A connector as recited in claim 8 , the body further comprising fibers within the cured resinous or thermoplastic material.
10. A connector as recited in claim 1 , the anchoring means comprising at least one of a recess, a hole, a ridge, a protrusion, a flange, a depression, a notch, an extension, or other irregularity disposed on or within the body.
11. A connector as recited in claim 1 , at least one of the sidewalls comprising an angled face at or near the tapered end.
12. A connector as recited in claim 1 , at least one of the sidewalls terminating with a chisel-like edge at or near the vicinity of the tapered end.
13. A connector as recited in claim 1 , the tapered end terminating at a substantially straight edge.
14. A connector as recited in claim 1 , the tapered end terminating at a curved edge.
15. A connector as recited in claim 1 , the tapered end terminating at a substantially sharp edge.
16. A connector as recited in claim 1 , the tapered end terminating at a substantially blunt edge.
17. A connector as recited in claim 1 , the body further comprising a trailing wall extending at least partially between the sidewalls at an end of said body within the trailing segment.
18. A connector as recited in claim 1 , the connector being sized and configured so as to provide from about 50% to 100% composite action within an insulating composite wall structure.
19. A connector as recited in claim 1 , the connector being sized and configured so as to provide at least about 60% composite action within an insulating composite wall structure.
20. A connector as recited in claim 1 , the connector being sized and configured so as to provide at least about 70% composite action within an insulating composite wall structure.
21. A connector as recited in claim 1 , the connector being sized and configured so as to provide at least about 80% composite action within an insulating composite wall structure.
22. A connector as recited in claim 1 , the connector being sized and configured so as to provide at least about 90% composite action within an insulating composite wall structure.
23. A connector for use in making an insulating composite wall structure, the connector comprising a body having a penetrating segment configured to reside within a first structural layer, a trailing segment configured to reside within a second structural layer, and a mesial segment between the penetration and trailing segments configured to reside within an insulating layer when the connector is in use, the body comprising:
two sidewalls;
a web portion extending between the two sidewalls;
a tapered end configured to facilitate penetration of the connector through an insulating layer and a layer of unhardened structural material adjacent to the insulating layer;
at least one protrusion extending laterally from the web portion at or near where the mesial and trailing segments intersect;
at least one of a recess, hole, ridge, protrusion, flange, depression, notch, or extension within the penetrating segment; and
at least one of a recess, hole, ridge, protrusion, flange, depression, notch, or extension within the trailing segment.
24. A connector as recited in claim 23 , the body further comprising a trailing wall extending at least partially between the sidewalls at an end of said body within the trailing segment.
25. A method of manufacturing a composite wall structure, comprising:
providing at least one connector as recited in claim 1;
placing an insulating layer adjacent to a first layer of unhardened structural material;
inserting the at connector through an exposed side of the insulating layer so that the mesial segment resides within the insulating layer and the penetrating segment resides within the first layer of unhardened structural material;
placing a second layer of unhardened structural material adjacent to the exposed side of the insulating layer in order for the trailing segment of the connector to reside within the second layer of unhardened structural material; and
allowing the first and second layers of unhardened structural material to harden.
26. A connector as recited in claim 25 , first and second layers of unhardened structural material hardening substantially simultaneously.
27. A connector as recited in claim 25 , first and second layers of unhardened structural material hardening sequentially.
28. A method of manufacturing a composite wall structure, comprising:
providing at least one connector as recited in claim 23;
placing an insulating layer adjacent to a first layer of unhardened structural material;
inserting the at connector through an exposed side of the insulating layer so that the mesial segment resides within the insulating layer and the penetrating segment resides within the first layer of unhardened structural material;
placing a second layer of unhardened structural material adjacent to the exposed side of the insulating layer in order for the trailing segment of the connector to reside within the second layer of unhardened structural material; and
allowing the first and second layers of unhardened structural material to harden.
29. A connector as recited in claim 28 , first and second layers of unhardened structural material hardening substantially simultaneously.
30. A connector as recited in claim 28 , first and second layers of unhardened structural material hardening sequentially.
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US10/254,168 US20040055247A1 (en) | 2002-09-25 | 2002-09-25 | High strength composite wall connectors having a tapered edge |
US10/626,127 US6895720B2 (en) | 2002-09-25 | 2003-07-23 | High strength composite wall connectors having tapered or pointed ends |
CA2442207A CA2442207C (en) | 2002-09-25 | 2003-09-23 | High strength composite wall connectors having tapered or pointed ends |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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US10/254,168 US20040055247A1 (en) | 2002-09-25 | 2002-09-25 | High strength composite wall connectors having a tapered edge |
Related Child Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US10/626,127 Continuation-In-Part US6895720B2 (en) | 2002-09-25 | 2003-07-23 | High strength composite wall connectors having tapered or pointed ends |
Publications (1)
Publication Number | Publication Date |
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US20040055247A1 true US20040055247A1 (en) | 2004-03-25 |
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US10/254,168 Abandoned US20040055247A1 (en) | 2002-09-25 | 2002-09-25 | High strength composite wall connectors having a tapered edge |
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Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2008144790A2 (en) * | 2007-05-31 | 2008-12-04 | Franz Oberndorfer Gmbh & Co | Connecting element and cavity wall element comprising connecting elements of this type |
US20090013631A1 (en) * | 2004-08-10 | 2009-01-15 | Devalapura Ravi K | High strength composite wall panel system |
USD764266S1 (en) | 2015-06-26 | 2016-08-23 | Hk Marketing Lc | Composite action tie |
USD804288S1 (en) | 2015-08-24 | 2017-12-05 | Hk Marketing Lc | Tie for composite wall |
USD856122S1 (en) | 2018-07-13 | 2019-08-13 | Hk Marketing Lc | Tie |
USD856121S1 (en) | 2018-01-29 | 2019-08-13 | Hk Marketing Lc | Composite action tie |
US10870988B2 (en) | 2018-01-29 | 2020-12-22 | Hk Marketing Lc | Tie for composite wall system fitting between insulation sheets |
USD968199S1 (en) | 2019-04-23 | 2022-11-01 | Hk Marketing Lc | Tie standoff |
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US20030070379A1 (en) * | 2001-10-12 | 2003-04-17 | Wall-Ties & Forms, Inc. | Attachment element for use with concrete wall and method employing same |
Cited By (12)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20090013631A1 (en) * | 2004-08-10 | 2009-01-15 | Devalapura Ravi K | High strength composite wall panel system |
US8397455B2 (en) | 2004-08-10 | 2013-03-19 | Owens Corning Intellectual Capital, Llc | High strength composite wall panel system |
WO2008144790A2 (en) * | 2007-05-31 | 2008-12-04 | Franz Oberndorfer Gmbh & Co | Connecting element and cavity wall element comprising connecting elements of this type |
WO2008144790A3 (en) * | 2007-05-31 | 2009-04-30 | Franz Oberndorfer Gmbh & Co | Connecting element and cavity wall element comprising connecting elements of this type |
USD764266S1 (en) | 2015-06-26 | 2016-08-23 | Hk Marketing Lc | Composite action tie |
USD804288S1 (en) | 2015-08-24 | 2017-12-05 | Hk Marketing Lc | Tie for composite wall |
US10000928B2 (en) | 2015-08-24 | 2018-06-19 | Hk Marketing Lc | Tie for composite wall system that is both screwable and axially pushable |
USD856121S1 (en) | 2018-01-29 | 2019-08-13 | Hk Marketing Lc | Composite action tie |
USD887258S1 (en) | 2018-01-29 | 2020-06-16 | Hk Marketing Lc | Composite action tie |
US10870988B2 (en) | 2018-01-29 | 2020-12-22 | Hk Marketing Lc | Tie for composite wall system fitting between insulation sheets |
USD856122S1 (en) | 2018-07-13 | 2019-08-13 | Hk Marketing Lc | Tie |
USD968199S1 (en) | 2019-04-23 | 2022-11-01 | Hk Marketing Lc | Tie standoff |
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