Abstract: Connectors used in manufacturing composite wall structures to substantially prevent forms from being displaced in response to pressure generated by concrete poured between the forms. In a completed composite wall structure, the connectors extend through two structural layers and an insulating layer positioned therebetween. The composite wall structures are formed by positioning the insulating layer between and in a spaced-apart relationship to the two forms. The connectors are subsequently inserted through the insulating layer and the forms. As concrete is then poured into spaces between the forms and the insulating layer, a bearing surface on a form retention segment, which extends beyond the outer surface of the forms, abuts the forms and prevents them from moving away from the insulating layer. The bearing surface is either directly positioned on the form retention segment or on a form locking device attached to the form retention segment.

Abstract: Methods for manufacturing highly insulating connector rods and highly insulating composite wall structures using such connector rods. The connector rods are highly insulating and are injection molded in a single step from an appropriate resinous material or moldable plastic. Discontinuous fibers may be impregnated within the resinous material or other moldable plastic. The single-step molding method yields connector rods having pointed ends for facilitating entry through an insulating layer and a first structural layer not yet cured, and also an enlarged head for receiving an impact from a hammer or mallet or for facilitating gripping by the installer. The enlarged head also provides an anchoring effect within a second structural layer upon curing. The connector rods are manufactured to include a ridge or flange to limit the depth of penetration by the connector rod when inserted into the insulating material when forming the composite wall structure.

Abstract: A connector used in forming a composite wall structure that includes two structural layers and an insulative layer. The connector secures the two structural layers together and is insulative so as to minimize the transfer of thermal energy across the insulating layer. The connector is inserted through the insulating layer during manufacturing of the wall structure. The connectors include reinforcement attaching structures for securing reinforcement material in a substantially fixed position before and during formation of the structural layers. The reinforcement attaching structures may be integrally formed on the connector or may be included on a bracket plate that is attached to the main shaft of the connector.

Abstract: Methods for manufacturing highly insulating connector rods and highly insulating composite wall structures using such connector rods. The connector rods are highly insulating and are injection molded in a single step from an appropriate resinous material or moldable plastic. Discontinuous fibers may be impregnated within the resinous material or other moldable plastic. The single-step molding method yields connector rods having pointed ends for facilitating entry through an insulating layer and a first structural layer not yet cured, and also an enlarged head for receiving an impact from a hammer or mallet or for facilitating gripping by the installer. The enlarged head also provides an anchoring effect within a second structural layer upon curing. The connector rods are manufactured to include a ridge or flange to limit the depth of penetration by the connector rod when inserted into the insulating material when forming the composite wall structure.

Abstract: Methods for manufacturing highly insulating connector rods and highly insulating composite wall structures using such connector rods. The connector rods are highly insulating and are injection molded in a single step from an appropriate resinous material or moldable plastic. Discontinuous fibers may be impregnated within the resinous material or other moldable plastic. The single step molding method yields connector rods having pointed ends for facilitating entry through an insulating layer and a first structural layer not yet cured, and also an enlarged head for receiving an impact from a hammer or mallet or for facilitating gripping by the installer. The enlarged head also provides an anchoring effect within a second structural layer upon curing. The connector rods are manufactured to include a ridge or flange to limit the depth of penetration by the connector rod when inserted into the insulating material when forming the composite wall structure.

Abstract: Multi-pronged insulating connectors used in manufacturing insulative composite wall structures. At least a substantial portion of the connector is injection molded in a single step from an appropriate resinous material or moldable plastic. One or more prongs of the connector have a substantially pointed end for facilitating penetration of the connector through an insulating layer and an unhardened structural material, such as concrete. The opposite end, or gripping segment, includes a bridging structure for connecting the multiple prongs together and structure for facilitating gripping of the connector during placement in the insulating layer and first unhardened structural layer. The connectors include structures for helping to anchor the connectors within the structural layers upon hardening.

Abstract: Highly insulating and substantially pointed connector rods used in making highly insulative composite wall structures. At least a substantial portion of the connector rod is injection molded in a single step from an appropriate resinous material or moldable plastic. The connector rod has a first substantially pointed end in a penetrating segment for facilitating entry through an insulating layer and for making abutting contact with a form sidewall when manufacturing a composite wall structure using a cast-in-place method. The opposite end, or trailing segment, also includes a substantially pointed end that makes abutting contact with another form sidewall. A middle or mesial segment resides within the insulating layer, which is sandwiched between two structural layers of a hardenable material, such as concrete. A first ridge or flange at the intersection between the mesial and trailing segments limits the depth of penetration of the connector rod when inserted through the insulating material.

Abstract: Highly insulating connectors used in making highly insulative composite wall structures. At least a substantial portion of the connector is injection molded in a single step from an appropriate resinous material or moldable plastic. The connector has a substantially pointed end in a penetrating segment for facilitating penetration of the connector through an insulating layer and a yet unhardened structural material, such as concrete, that will harden into a first structural layer. The opposite end, or gripping segment, includes arcuate wings for facilitating gripping of the connector during placement in the insulating layer and first unhardened structural layer, and also for anchoring the connectors upon hardening of a second structural layer. A middle or mesial segment resides within the insulating layer, which is sandwiched between the first and second structural layer.

Abstract: Highly insulating connector rods used in making highly insulative composite wall structures are disclosed. The high R-value connector is injection molded in a single step from an appropriate resinous material or moldable plastic. Discontinuous fibers may be impregnated within the resinous material or other plastic. The connector rod has a pointed end for facilitating entry through an insulating layer and a first structural layer and an enlarged head for receiving an impact from a hammer or mallet. The enlarged head also provides an anchoring effect within a second structural layer. A ridge or flange helps to orient the connector rod when inserted into the insulating material and also helps to prevent the collapse of the second structural layer toward the first structural layer.