Insulating connectors for securing insulation to an existing structure

Abstract

The present invention includes connectors that are configured for securing an insulating layer to existing structures. The connectors are composed of a thermally insulating material to prevent undesired thermal bridging through the insulating layer. The connectors include enlarged contact surfaces and stems that are configured to prevent the connector from undesirably compressing, passing entirely through, or otherwise damaging the insulating layer. The connectors are configured to mount to the existing structure or to be coupled with embeds that are placed within the structural layer of a composite wall. The connectors may also include structure for interconnecting other wall layers to the composite wall and structure for slidably engaging a flat concrete tie.

Description

BACKGROUND OF THE INVENTION

[0001] 1. The Field of the Invention

[0002] The present invention is in the field of wall connectors and, more particularly, in the field of mounting brackets and wall embeds that are used to secure a layer of insulation material to an existing structure.

[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 are laminated with highly insulative materials to provide a composite wall structure of both high strength and high insulation.

[0005] Concrete is one of the least expensive and strongest building materials found in the construction industry. Concrete 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. Although concrete forms a relatively high strength, low cost building material, it also has the drawback of offering relatively poor insulation compared to materials such as fiberglass and polymeric foam materials. Brick is another common building material and is held together using cement-based mortar.

[0006] A commonly used measurement of the thermal insulating qualities of a material is the mathematical coefficient “R” which is a measure 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 of ordinary skill in the art as possessing a high thermal resistance or insulating ability.

[0007] While an 8.0 inch slab of concrete has an R value of 0.64, a 1.0 inch panel of polystyrene has an R value of 5.0. Accordingly, a 1.0 inch panel of polystyrene can provide nearly as much insulation as an 8.0 inch slab of concrete. Although polystyrene and other similar insulating materials exhibit superior insulating properties to concrete, it is impractical to construct structural walls entirely out of insulating materials because insulating materials offer little or no structural strength. Accordingly, whereas a wall composed of only concrete may not provide desired insulating properties, a wall composed of only insulating material may lack adequate structural support.

[0008] A composite wall overcomes the aforementioned limitations, by providing a structural layer that exhibit the desired structural properties and a layer of insulation that provides the desired insulating properties. For example, a concrete or brick wall that is structurally sound can be laminated with a layer of insulation that is capable of preventing, or at least slowing, the transfer of thermal energy through the composite wall structure. The composite wall structure may also include an outer layer that is placed over the insulating layer to protect the insulation and to provide a desired aesthetic appearance to the composite wall structure.

[0009] Attaching the insulating layer to concrete, brick or other existing structures can be performed with various connecting devices. Existing connecting devices typically comprise anchoring bolts or brackets that are configured to penetrate the insulating layer and to mount the insulating layer to a metal stud or beam that is integrally attached to the structural layer. The insulating layer is secured against the structural layer of the composite wall by compressive forces that are applied when the connecting devices are secured to the metal stud or beam of the wall structure. The outer layer of the composite wall can also be secured to the structural layer of the composite wall when wire or other elements that extend away from the connecting devices are attached to the outer layer.

[0010] One problem with existing connecting devices, however, is that they are typically manufactured out of metal and can, therefore, compromise the insulation that is provided by the insulating layer. In particular, structural bridging of the composite wall layers with metallic connecting devices creates a conductive thermal bridge across which heat can readily flow, even when the connecting devices are 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, through the connecting devices. 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.

[0011] Another problem with certain existing connecting devices is that when they are attached to the anchoring support (e.g., metal beam) they can be driven entirely through the insulating layer, such that they are unable to support and hold the insulating layer in a desired placement against the structural layer of the composite wall. Additionally, even when the connecting devices do not pass entirely through the insulating layer, the connecting devices may still be tightened to such a degree that the insulating layer is excessively compressed, cracked, or otherwise damaged by the connecting devices, creating undesired passageways through which air and heat can flow, thereby compromising the integrity and insulating properties of the insulating layer.

[0012] Damage that is caused to the insulating layer by the connecting devices can also compromise the “composite action” of the wall. Composite action, which is well known by those of ordinary skill in the art, generally describes how well a composite wall transfers shear forces between its different layers and behaves like a single composite wall. It is typically desirable to produce composite walls having high composite action so that they will remain intact when loads are applied to the wall. Accordingly, it is undesirable to damage the insulating layer with the connecting devices in a manner that may compromise the structural integrity and composite action of the resultant wall.

[0013] For at least the forgoing reasons, there is currently a need in the art for improved connecting devices configured to secure together insulating and structural layers of composite wall structures.

SUMMARY OF PRESENTLY PREFERRED EMBODIMENTS

[0014] Briefly summarized, the present invention is directed to improved connectors that are configured to secure a layer of an insulation material to an existing non-insulating structure.

[0015] According to one aspect of the invention, the connectors are composed at least partially out of a thermal insulating material, so as to reduce thermal bridging through the composite wall structure. The connectors may include one or more of high strength resins, fibers and fillers to impart sufficient strength to the connecting devices.

[0016] According to another aspect of the invention, the connectors include a body having an enlarged contact surface that is configured to engage an exposed surface of the insulating layer in such a manner as to help prevent the connectors from undesirably damaging or passing entirely through the insulating layer, thereby preserving the capabilities of the connectors to hold the insulating layer against the structural layer.

[0017] The connectors may also include means for separating the enlarged contact surface of the connectors from the structural surface by a predetermined distance to further help prevent the inventive connectors from damaging or passing entirely through the insulating layer. The predetermined distance will typically correspond to the thickness of the insulating layer.

[0018] In one embodiment, the separating means includes one or more stems that protrude away from the enlarged contact surface of the connectors. The stems are configured to pass through the insulating layer and to engage the structural layer of a composite wall when the connectors are positioned a predetermined distance from the structure surface. Upon engaging the structural layer, the stems effectively prevent the connectors from passing any further through the insulation layer.

[0019] In certain embodiments, the connectors also include sealing means such as washers or raised surfaces for improving the seal between the connectors and the insulating layer, so as to help preserve the insulating properties of the insulating layer.

[0020] The connectors may also include means for interconnecting another wall layer to the composite wall. Additional wall layers may include, but are not limited to, a wire mesh filament layer used for stucco walls and a brick wall layer. The means for interconnecting the additional wall layers may include mounting structures that protrude away from the connectors and that are configured to engage the additional wall layers or other objects such as brick ties and wires that are connected to the additional wall layers.

[0021] The connectors may also include coupling means for coupling the connectors to the composite wall and, more particularly, to the structural layer of the composite wall. For instance, the aforementioned stems may be hollow, and the coupling means may include a screw or a bolt that is disposed within the hollow stems and that is configured to securely couple with the structural layer of the composite wall. The coupling means may alternatively include threading that is disposed on the stems themselves, such that the stems are configured to threadably engage the insulation layer and structural layer of the composite wall.

[0022] In another embodiment, the coupling means may comprise embeds that are hollowed and configured to receivably and securely engage one or more stems of the connectors, or one or more screws or bolts passing through hollow stems. The embeds may engage the connectors with a bayonet-type connection or a snap-fit connection. The embeds may also be configured to threadably engage a corresponding threaded portion of the connectors. In certain embodiments, the embeds may include anchoring means such as ridges, tapers, and other structures for anchoring the embeds within the structural wall.

[0023] It will be appreciated that by strategically placing the embeds at a desired placement within the structural layer, it is possible to predetermine the distance in which the contact surface of the connectors will be separated from the structural layer. The embeds may, for example, be secured within the structural layer of the wall prior to the placement of the connectors within the wall. In one embodiment, the embeds are secured within the structural layer of the wall during formation of the structural layer, thereby becoming an integral part of the structural layer as the structural material (e.g, concrete or mortar) hardens. The embeds may also include structure that is configured to slidably engage and mount to a flat strap within the structural layer, such as a concrete tie.

[0024] 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

[0025] 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:

[0026] FIG. 1 illustrates a rear perspective view of an embodiment of a connector according to the invention that includes a body, two hollow stems and a mounting structure;

[0027] FIG. 2 illustrates a front perspective view of the connector of FIG. 1 in order to better illustrate an enlarged contact surface on the face of the connector;

[0028] FIG. 3 illustrates a rear perspective view of the connector of FIG. 1 in which screws have been preloaded into each of the two hollow stems;

[0029] FIG. 4 illustrates a cross-sectional side view of the connector of FIG. 3 connecting an insulating layer to a structural wall together with a connecting tie wire disposed within a mounting structure of the connector;

[0030] FIG. 5 illustrates a front perspective view of the connector of FIG. 1 in which seals have been placed over each of the stems;

[0031] FIG. 6 illustrates a front perspective view of the connector in FIG. 1 in which the enlarged contact surface includes raised surfaces surrounding each of the stems;

[0032] FIG. 7 illustrates an embodiment of a connector according to the invention that includes a single stem and a mounting structure configured to be connected with a brick tie wire;

[0033] FIG. 8 illustrates an embodiment of a connector according to the invention that includes a single stem and an enlarged contact surface, in which the single stem is configured to engage a structural layer and to separate the enlarged contact surface of the connector from the structural layer by a predetermined distance;

[0034] FIG. 9 illustrates an embodiment of a connector according to the invention that includes a single stem, an enlarged contact surface, and a mounting structure configured to be connected with a wire mesh filament for making a stucco wall;

[0035] FIG. 10 illustrates an embodiment of a connector according to the invention that includes a stem and an embed that are initially separated, wherein the stem is configured to snap-fit into the embed;

[0036] FIG. 11 illustrates the connector of FIG. 10 in which the stem is coupled to the embed with a snap-fit connection;

[0037] FIG. 12 illustrates an embodiment of a connector according to the invention that includes a stem and an embed that initially separated, wherein the stem is configured to couple with the embed in a bayonet-type connection;

[0038] FIG. 13 illustrates the connector of FIG. 12 in which the stem is coupled with the embed in a bayonet-type connection;

[0039] FIG. 14 illustrates an embodiment in which an inventive embed that is tapered is anchored within a structural layer and ready to receive a stem of a connector;

[0040] FIG. 15 illustrates an embodiment in which an inventive embed has a tapered base that is anchored within a structural layer and that is threaded so as to receive a threaded bolt or screw of a connector;

[0041] FIG. 16 illustrates an embodiment of an inventive embed that includes wing structures that are configured to slidably engage a flat concrete tie;

[0042] FIG. 17 illustrates a partial cross-sectional top view that shows the embed of FIG. 16 connected to a flat concrete tie within a structural layer of a wall; and

[0043] FIG. 18 illustrates a partial cross-sectional bottom view that shows the embed of FIG. 16 connected to a flat concrete tie within a structural layer of a wall.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0044] 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.

[0045] The embodiments of the present invention are generally directed to improved connectors and embeds that are used for connecting the layers of a composite wall. The term “composite wall,” as defined herein, generally refers to a wall or layered structure that includes at least an insulating layer and a structural layer (e.g., a concrete or brick wall). The composite wall may also include other layers, such as, but not limited to a brick layer and a stucco layer. Each layer of the composite wall may also be composed of a plurality of layers. For instance, the insulating layer may comprise a plurality of laminated insulation layers.

[0046] In one embodiment, the connectors and embeds of the invention are composed of a thermally insulating material. 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.

[0047] Examples of suitable thermoplastic and thermosetting plastic materials that may be used to manufacture the connectors and embeds of the invention include, but are not limited to polyphthalamide, polyphenylsulfone, polypropylene, polyethylene, polysulfone, polyethersulfone, polyketone, polyamideimide, polystyrenes, nylon, acrylic, and polyester. Other suitable materials also include polyamides, polycarbonates, polyphthenyl sulfones, aliphatic polyketones, 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, dialoyl phthalates, epoxy resins, furan resins and phenolic resins. Copolymers and blends of the foregoing materials may also be used.

[0048] The connectors of the invention are preferably injection molded from any appropriate resin or other high strength plastic material, such as those mentioned above, although they may also be molded by resin transfer molding, reaction injection molding, or any other molding process known in the art.

[0049] Although not necessary in many instances, it may be desirable to incorporate within the resinous material or other plastic material fillers or 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.

[0050] Attention is now directed to FIGS. 1 and 2, which illustrate an embodiment of a connector 10 according to the invention. FIG. 1 illustrates a back perspective view of the connector 10 and FIG. 2 illustrates a front perspective view of the connector 10. As shown, the connector 10 includes a body having an enlarged contact surface 12 that is substantially planar. It will be appreciated, however, that the enlarged contact surface 12 may also be beveled, textured, or curved. The primary function of the enlarged contact surface 12 is to provide a suitable surface for engaging the insulating layer of a composite wall. The enlarged contact surface 12 helps to prevent the connector 10 from undesirably damaging or passing entirely through the insulating layer of a composite wall, as described below in reference to FIG. 4.

[0051] The connector 10 also includes one or more stems 14 that protrude away from the enlarged contact surface 12. The stems 14 may be hollow, as shown, or they may be solid. One benefit of providing hollow stems 14 is that they can be used or preloaded with bolts or screws 16 (shown in FIG. 3), or other coupling means for coupling the connector to a composite wall.

[0052] FIG. 4 shows the connector 10 being used to secure an insulating layer 30 to a structural layer 40 (e.g., an existing concrete or masonry wall). As shown, the stems 14 are configured to pass through the insulating layer 30 until they engage the structural layer 40 of the composite wall. Upon engaging the structural layer 40, the stems 14 function as a means for separating the enlarged contact surface 12 from the structural layer 40 of the composite wall. This helps to prevent the enlarged contact surface 12 from undesirably damaging, compressing, or passing through the insulating layer 30. The length of the stems 14 can be predetermined at the time of manufacture to control the distance in which the enlarged contact surface 12 is spaced away from the structural layer 40. Preferably, at least the stems 14 are composed of a thermally insulating material.

[0053] To secure the connector 10 to the structural layer 40 of the composite wall, a coupling means such as the illustrated screws 16 may be used. The screws 16 may be preloaded into the stems 14, as shown in FIG. 3, prior to placing the connector 10 on the composite wall or the screws 16 may be supplied subsequent to placing the connector 10 in a desired placement on the wall. The screws 16 may be self-tapping (e.g., where the structural layer is relatively soft or unhardened) and/or configured to threadably engage holes within the structural layer 40 of the wall. The screws 16 or other coupling means may be configured to engage embeds or other structures disposed within the structural layer 40 of the wall.

[0054] According to yet another embodiment, the coupling means may include the stems of the connector when the stems are configured to engage embeds located within the structural layer 40 of the wall, as described below in reference to FIGS. 10-14.

[0055] As shown in FIG. 4, the enlarged contact surface 12 is configured to engage the insulating layer 30 of the composite wall. The surface area of the enlarged contact surface 12 helps to support the connector 10 against the insulating layer 30 and to prevent the enlarged contact surface 12 from passing through the insulating layer 30. The planar surface of the enlarged contact surface 12 also helps to seal the holes in the insulating layer through which the stems 14 and the screws 16 may pass.

[0056] To further seal the enlarged contact surface 12 with the insulating layer 30, and to help preserve the insulating properties of the insulating layer 30, the connector 10 may also include sealing means, as shown in FIGS. 5 and 6.

[0057] FIG. 5 illustrates a connector 10 with rubber seals 22 that are disposed around the stems 14 of the connector 10. The use of rubber seals 22, gaskets, and other similar sealing means can help to create a seal between the enlarged contact surface 12 and the insulating layer 30 around the holes that are formed in the insulating layer 30, when the connector 10 is properly secured to the composite wall. Another example of a suitable sealing means includes the raised surfaces 23 that protrude out of the enlarged contact surface 12 around the stems 14 of the connector 10 shown in FIG. 6. The raised surfaces 23 may be flattened, as shown, or else they may be tapered.

[0058] The connector 10 of the present embodiment may also include means for interconnecting another wall layer to the composite wall. For instance, as shown in FIGS. 1 and 3-4, the connector 10 may include interconnecting means comprising mounting structure 18 that protrudes away from the connector 10. The mounting structure 18 may include holes 20 for engaging and securing other objects such as brick ties and wires that are connected to the additional wall layers. In the embodiment illustrated in FIG. 4, a brick tie is mounted to the connector 10 through a hole 20 formed in the mounting structure 18. The illustrated brick tie may thereafter be embedded within the mortar of a brick wall. Auxiliary holes 19 may also be used to attach wire or other structures to the connector 10.

[0059] Attention is now directed to FIG. 7, which illustrates another connector 100 according to the invention. As shown, the connector 100 includes a body with only a single stem 110 that is solid and threaded, and which protrudes away from an enlarged contact surface of the body. This threading is useful for helping to thread the connector 100 through the insulating layer of a composite wall. The threading also permits the stem 110 to threadably engage the structural layer. In other embodiments, the connector 100 may be configured with a hollow stem (not shown, but as generally described above with reference to FIG. 3), for receiving a screw or other coupling means.

[0060] FIG. 8 illustrates a stem 110 that is bifurcated into two distinct sections, a tip section 112 and a support section 114. In this embodiment, the support section 114 has a greater diameter than the tip section 112, such that when the stem 110′ is inserted through the insulation layer (not shown), the support section 114 abuts against the structural layer (not shown) and functions as a means for separating the enlarged contact surface 116 from the structural layer. The tip section 112 is configured to threadably engage the structural layer or embed that is placed within the structural layer.

[0061] The connector 100 shown in FIG. 7 includes means for interconnecting another wall layer to the composite wall. In particular, the connector 100 includes a mounting structure 118 that protrudes away from the connector. The mounting structure 118 is shown in the present embodiment as a closed loop that is configured to receivably engage a wire, a brick tie or other object that can be connected with another wall layer, as described above with reference to the mounting structure 18 of FIG. 1.

[0062] The mounting structure 118 can also be used to facilitate insertion of the connector 100 through insulating and structural layers. In particular, the mounting structure 118 can be held and turned with a tool or by hand while threadably inserting the connector 100 within the composite wall.

[0063] FIG. 9 illustrates another embodiment of a connector 200 according to the invention. In this embodiment, the connector 200 includes mounting structures 218 that are configured to engage a wire mesh that may be used when applying stucco exterior to the composite wall. The connector 200 of this embodiment also includes an engagement structure 220 that may be grasped with a tool such as pliers or a wrench when placing the connector 200 within the composite wall. Although the engagement structure 220 is shown to protrude away from the connector 200, it will be appreciated that the engagement structure 220 may also be recessed within the connector 200. For instance, the engagement structure 220 may comprise a recess that is configured to receive an allen wrench or other tool for placing the connector 200 within the composite wall.

[0064] FIG. 10 illustrates an embodiment of a connector 300 that includes a stem 310 that is configured to engage an embed 350. More particularly, the stem 310 of the connector 300 includes a tip 312 that is configured to snap into a hollow interior 354 of the embed 350. FIG. 10 also illustrates a cross-sectional side view of the embed 350 that is configured to receivably engage the tip 312 of the connector with a snap-fit type connection. As shown, the embed 350 includes a hollow interior 354 and ridges 360 that are configured to engage corresponding ridges 370 on the connector 300 when the tip 312 of the connector 300 is inserted within the hollow interior 354 of the embed 350.

[0065] FIG. 11 illustrates how the connector 300 may be securely engaged within the hollow interior 354 of the embed 350 with a snap-fit type connection. As shown, the tip 312 of the connector 310 has been inserted within the embed 350 so that the ridges 360 of the embed 350 engage the ridges 370 of the tip 312, thereby locking the tip 312 within the hollow portion 354 of the embed 350.

[0066] In another embodiment, illustrated in FIGS. 12 and 13, a tip 412 of a connector 400 is configured to be inserted and rotated within an embed 450. However, instead of being configured with a tip that is suitable for a snap-fit type connection, the tip 412 of the present embodiment is configured to engage the embed 450 with a bayonet-type connection. In particular, the tip 412 is configured with a slightly oval cross-sectional back end 460 that is designed to be inserted into an oval opening 470 that is formed within the embed 450. Once the tip 412 has been inserted within the oval opening 470 of the embed 450, the connector 450 can be rotated to lock the tip 412 of the connector 400 within the embed 450 in a bayonet-type connection, as shown in FIG. 13. Notice that the connector 400 has been rotate about 90° from the position shown in FIG. 12, thereby locking the connector 400 with embed 450.

[0067] In one embodiment, the embeds of the invention are placed within the existing structure prior to attachment of the insulating layer thereto. For instance, if the structural layer is formed of concrete then the embeds may be placed within the concrete before the concrete cures and solidifies. To help maintain the embed within the structural layer, the embeds may be configured with anchoring means, such as a taper, ridge, protrusion, or other structure that can help secure the embed within the structural layer. As a mater of example, and not limitation, the ridges 380 and 480 that circumferentially extend around the bases of the embeds 350 and 450, respectively, comprise suitable means for anchoring the embeds within the structural layer of a composite wall.

[0068] FIG. 14 illustrates another example in which an embed 500 according to the invention includes means for anchoring the embed 500 within a structural layer. In particular, the embed 500 includes a tapered sidewall 510 that helps to anchor the embed 500 within the structural layer 520 when hardened or cured. The embed 500 is also configured to receivably engage a tip 530 of a connector, as described above in reference to FIGS. 10 and 11. It will be appreciated, however, that the embed 500 may also be configured to engage a connector with a bayonet-type connection or any other type of connection.

[0069] FIG. 15 illustrates how an embed 600 may also be configured with internal threading to threadably engage a tip 610 of a connector. The embed 600 in the present embodiment is also configured with a tapered base 620, which functions as a suitable means for anchoring the embed within the structural layer 630 when hardened or cured.

[0070] Attention is now directed to FIGS. 16-18, which illustrate yet another type of embed 700 that may be configured to be used in combination with the connectors of the invention. As shown, the embed includes wing structures 710 that protrude away from a hollow body 720 of the embed 700. The wing structures 710 are specifically configured with edges 730 that are designed to slidably engage the edges of a flat strap, such as a concrete tie. It will be appreciated that this is useful for helping to secure the embed 700 within the structural layer of a composite wall at a desired placement. The wing structures 710 also provide additional anchoring means for anchoring the embed within the structural layer once it solidifies.

[0071] FIG. 17 illustrates a partial cross-sectional top view of the embed 700 after it has been mounted to a flat strap, such as concrete tie 740, within a structural layer 750. FIG. 18 illustrates a partial cross-sectional bottom view of the embed 700 mounted to the concrete tie 740. As shown, the edges 730 of the embed 700 slidably engage the sides of the concrete tie 740. This helps to provide a desired alignment and stability to the embed 700. It will be appreciated that the illustrated embed 700 may be configured to receivably engage any of the connectors that have described herein. In particular, the embed 700 may be configured with a hollow body designed for bayonet-type coupling, a hollow body designed for snap-fit coupling, or with threading for threaded coupling.

[0072] In summary, the connectors of the present invention help to maintain and preserve the thermal insulation that is provided by the thermally insulating layer of a composite wall. This is accomplished, according to one aspect of the invention, by manufacturing the connectors out of a thermally insulating material, thereby helping to prevent thermal bridging through the thermally insulating layer.

[0073] In certain embodiments, the connectors of the invention include enlarged contact surfaces that are configured to engage the insulating layer of a composite wall without undesirably damaging or passing through the insulating layer. The connectors may also include stems that are configured to separate the enlarged surface from a structural layer of the composite wall by a predetermined distance. In certain embodiments, the connectors are configured to securely couple with embeds that are placed within the structural layer of the composite wall. By securing the connector to the composite wall without damaging the insulating layer, the connectors of the invention are also able to help preserve desired composite action of the composite wall.

[0074] 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

1. A connector for use in connecting an insulating layer to a structural layer, the connector comprising:

a body;

an enlarged contact surface disposed on the body, the enlarged contact surface being configured to engage a surface of an insulating layer;

separating means for separating the enlarged contact surface from a structural layer by a predetermined distance, wherein the separating means is configured to pass at least partially through the insulating layer and to engage the structural layer, the separating means protruding away from the enlarged contact surface; and

interconnecting means for attaching a tie or wire of an outer wall layer to the connector,

wherein at least the separating means is composed of a thermally insulating material.

2. A connector as recited in claim 1, wherein the enlarged contact surface is planar.

3. A connector as recited in claim 1, wherein the separating means includes a stem that protrudes away from the enlarged contact surface.

4. A connector as recited in claim 3, wherein the stem is configured to threadably engage the insulating layer.

5. A connector as recited in claim 3, wherein the stem is hollow.

6. A connector as recited in claim 3, wherein the connector further includes a coupling means for coupling the connector with the structural layer.

7. A connector as recited in claim 6, wherein the coupling means includes at least one of a screw and a bolt that is disposed within the stem when coupling the connector with the structural layer.

8. A connector as recited in claim 6, wherein the coupling means includes an embed that is configured to be mounted to the structural layer.

9. A connector as recited in claim 8, wherein the embed includes anchoring means for anchoring the embed within the structural layer.

10. A connector as recited in claim 9, wherein the anchoring means includes at least one of a ridge and a taper that is configured to anchor the embed within the structural layer.

11. A connector as recited in claim 8, wherein the embed is configured to engage the stem of the connector with a bayonet-type connection, and wherein the embed is configured to be inserted at least partially within a hollow portion of the embed and to be rotated within the hollow portion of the embed.

12. A connector as recited in claim 8, wherein the embed is configured to engage the stem of the connector with a snap-fit type connection, and wherein the stem of the connector includes a tip that is configured to snap into a hollow portion of the embed.

13. A connector as recited in claim 8, wherein the embed includes structures protruding away from the embed that are configured to slidably engage a flat concrete tie.

14. A connector as recited in claim 1, further including a sealing means for helping to seal the enlarged contact surface with the insulating layer.

15. A connector as recited in claim 14, wherein the sealing means includes a rubber washer.

16. A connector as recited in claim 14, wherein the sealing means includes a raised surface that protrudes away from the enlarged contact surface.

17. A connector as recited in claim 3, where in the means for separating includes at least two stems that protrude away from the enlarged contact surface.

18. A connector as recited in claim 17, wherein each stem is configured to engage the structural layer when the enlarged contact surface is engaged with the insulating layer so as to prevent the enlarged contact surface from passing towards the structural layer beyond the predetermined distance.

19. A connector as recited in claim 1, wherein the interconnecting means includes mounting structure that protrudes away from the connector.

20. A connector as recited in claim 19, wherein the mounting structure is configured to engage a brick tie wire.

21. A connector as recited in claim 19, wherein the mounting structure is configured to engage a wire mesh.

22. A connector as recited in claim 1, wherein the thermally insulating material includes a material that is selected from the group of polyphenylsulfones resins, polypthalamides, polyamides, polyarylsulfones, polycarbonates, polysulfones, polyphthenyl sulfones, polyether sulfones, aliphatic polyketones, acrylics, nylons and polyesters.

23. A connector as recited in claim 22, wherein the thermally insulating material is combined with at least one of high strength resin, a fiber and a filler.

24. A connector for use in connecting an insulating layer to a structural layer, the connector comprising:

a body,

an enlarged contact surface disposed on the body, the enlarged contact surface being configured to conform to the shape of an insulating layer; and

a plurality of hollow stems protruding away from the enlarged contact surface, the stems being composed of a thermally insulating material and being configured to engage the structural layer when the enlarged contact surface is disposed a predetermined distance away from the structural layer; and

at least one screw disposed within at least one of the hollow stems, the at least one screw being configured to secure the connector to the structural layer.

25. A connector as recited in claim 24, wherein said at least one screw is self-tapping.

26. A connector as recited in claim 24, wherein each of the plurality of hollow stems includes a screw disposed therein.

27. A connector as recited in claim 24, wherein each of hollow stems further includes a sealing means disposed thereabout for sealing the enlarged contact surface with the insulating layer.

28. A connector as recited in claim 27, wherein said sealing means includes a raised surface about each hollow stem.

29. A connector as recited in claim 27, wherein said sealing means includes a rubber gasket disposed about each hollow stem.

30. A connector as recited in claim 24, further including mounting structure that protrudes away from the connector and that is configured to connect to a tie or wire.

31. A connector as recited in claim 30, wherein said tie or wire is connected to an outer layer comprising one of a stucco wall and a brick wall.

32. A connector as recited in claim 30, wherein said enlarged contact surface is flat.

33. A connector as recited in claim 24, wherein the thermally insulating material includes a material that is selected from the group of polyphenylsulfones resins, polypthalamides, polyamides, polyarylsulfones, polycarbonates, polysulfones, polyphthenyl sulfones, polyether sulfones, aliphatic polyketones, acrylics, nylons and polyesters.

34. A connector for use in connecting an insulating layer and a structural layer, the connector comprising:

a body;

an enlarged contact surface disposed on the body, the enlarged contact surface being configured to engage a surface of an insulating layer;

a stem protruding away from the enlarged contact surface, the stem being composed of a thermal insulating material and being configured to engage a structural layer; and

mounting structure protruding away from the connector that is configured to connect an outer layer to the composite wall.

35. A connector as recited in claim 34, wherein the stem is threaded.

36. A connector as recited in claim 35, wherein the stem is self-tapping.

37. A connector as recited in claim 34, wherein the stem is configured to couple with an embed that is mounted within the structural layer.

38. A connector as recited in claim 37, wherein the stem is configured to couple with the embed in a bayonet-type connection.

39. A connector as recited in claim 37, wherein the stem is configured to couple with the embed in a snap-fit connection.

40. A connector as recited in claim 37, wherein the stem is configured to couple with a threaded coupling.

41. A connector as recited in claim 34, wherein the mounting structure is configured to engage a wire mesh of a stucco wall.

42. A connector as recited in claim 34, wherein the mounting structure is configured to engage a brick tie wire.

43. A connector as recited in claim 34, wherein the thermally insulating material includes a material that is selected from the group of polyphenylsulfones resins, polypthalamides, polyamides, polyarylsulfones, polycarbonates, polysulfones, polyphthenyl sulfones, polyether sulfones, aliphatic polyketones, acrylics, nylons and polyesters.

44. An embed for use in connecting an insulating layer to a structural layer wall, the embed comprising:

a hollow body configured to be mounted within a structural layer, the hollow body being configured to receivably engage the stem of a connector; and

wing structures protruding away from the hollow body, the wing structures being configured to slidably engage a flat strap.

45. An embed as recited in claim 44, wherein the embed is configured to engage a connector for use in connecting an insulating layer and a structural layer, the connector including:

a body;

an enlarged contact surface disposed on the body, the enlarged contact surface being configured to engage a surface of the insulating layer;

at least one stem configured to separate the enlarged contact surface from the structural layer by a predetermined distance, wherein the at least one stem is configured to pass at least partially through the insulating layer and to engage the structural layer.

46. An embed as recited in claim 45, wherein the embed is configured to engage the connector with a bayonet-type coupling.

47. An embed as recited in claim 45, wherein the embed is configured to engage the connector with a snap-fit coupling.

48. An embed as recited in claim 45, wherein the embed is configured to engage the connector with a threaded coupling.

49. An embed as recited in claim 44, further including anchoring means for anchoring the embed within the structural layer when the structural layer is in a hardened state.

50. An embed as recited in claim 49, wherein the anchoring means includes a ridge circumferentially extending around the embed.

51. An embed as recited in claim 44, wherein the embed is composed of a thermally insulating material that is selected from the group of polyphenylsulfones resins, polypthalamides, polyamides, polyarylsulfones, polycarbonates, polysulfones, polyphthenyl sulfones, polyether sulfones, aliphatic polyketones, acrylics, nylons and polyesters.