U.S. patent application number 10/254168 was filed with the patent office on 2004-03-25 for high strength composite wall connectors having a tapered edge.
Invention is credited to Keith, David O..
Application Number | 20040055247 10/254168 |
Document ID | / |
Family ID | 31993278 |
Filed Date | 2004-03-25 |
United States Patent
Application |
20040055247 |
Kind Code |
A1 |
Keith, David O. |
March 25, 2004 |
High strength composite wall connectors having a tapered edge
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.
Inventors: |
Keith, David O.; (American
Fork, UT) |
Correspondence
Address: |
WORKMAN NYDEGGER (F/K/A WORKMAN NYDEGGER & SEELEY)
60 EAST SOUTH TEMPLE
1000 EAGLE GATE TOWER
SALT LAKE CITY
UT
84111
US
|
Family ID: |
31993278 |
Appl. No.: |
10/254168 |
Filed: |
September 25, 2002 |
Current U.S.
Class: |
52/782.24 |
Current CPC
Class: |
E04C 2002/046 20130101;
B28B 19/003 20130101; B28B 23/005 20130101; E04B 1/41 20130101 |
Class at
Publication: |
052/782.24 |
International
Class: |
E04B 002/00; E04C
002/00; E04C 002/54; A47B 013/08 |
Claims
What is claimed is:
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.
Description
BACKGROUND OF THE INVENTION
[0001] 1. The Field of the Invention
[0002] 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.
[0003] 2. The Relevant Technology
[0004] 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.
[0005] 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.
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
SUMMARY OF PRESENTLY PREFERRED EMBODIMENTS
[0013] 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.
[0014] 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.
[0015] 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.
[0016] 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.
[0017] 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.
[0018] 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.
[0019] 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.
[0020] 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.
[0021] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] 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:
[0023] 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;
[0024] 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;
[0025] FIG. 3 illustrates a perspective view of one embodiment of
the connector of the invention that includes a curved tapered
end;
[0026] 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;
[0027] 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;
[0028] FIG. 6 illustrates a front elevational cross-section view of
a partially completed composite wall structure; and
[0029] FIG. 7 illustrates a front elevational cross-section view of
a composite wall structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] 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.
[0031] 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.
[0032] 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.
[0033] 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."
[0034] 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.
[0035] 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.
[0036] 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.
[0037] 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.
[0038] 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.
[0039] 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 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.
[0040] As shown, the penetrating segment 20 includes a tapered end
26 that extends between the two sidewalls 14. According to one
embodiment, 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. Although 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. 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. 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".
[0041] 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 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. According to one
preferred embodiment, 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.
[0042] Although 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.
[0043] As shown in FIG. 1, 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. It will be appreciated, however, that 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.
According to another embodiment, 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.
[0044] Returning now to FIG. 1, it is shown how 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. It will be appreciated that 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. For instance, 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.
[0045] According to one preferred embodiment, 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. 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.
[0046] As shown in FIGS. 1-3, 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. In particular, 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.
[0047] As shown in FIG. 4, 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.
[0048] 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 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.
[0049] 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 first structural layer 60 adequate strength and the
ability to firmly anchor the penetrating segment 20 of the
connector 10 therein.
[0050] Before the first structural layer 60 obtains such rigidity
that a connector 10 cannot be inserted therein without damaging the
ultimate structural integrity and strength of the first structural
layer 60, 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.
[0051] 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. In order to insert the connector 10 to a desired
depth, it may be necessary to apply a driving force to the wall 40
of the connector 10. This 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.
Accordingly, the flange 44 comprises one suitable means for
orienting the connector 10 within the insulation layer 70 at a
predetermined depth.
[0052] Once the connector 10 is properly oriented within the
insulation layer 70, 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.
[0053] 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 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.
[0054] In some cases it may be desirable to lay 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.
[0055] 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.
[0056] 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.
[0057] 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.
* * * * *