Abstract: Ties and related methods for making insulating composite wall structures including first and second structural layers comprising a hardenable material and an insulating layer having a high thermal resistance disposed between the structural layers. The insulating layer is formed from a plurality of insulating sheets, where the sheets are sandwiched between the structural layers of the wall. During wall construction, the tie is configured to be advanced into the first structural layer before it has hardened, with the tie fitting between adjacent sheets of insulation. No pre-drilling of holes through the sheets, or screwing or pressing of the ties through the actual sheets is required. Each tie includes generally planar features to accommodate such placement, with a penetrating segment, an impact segment, and a mesial segment therebetween. At least the penetrating and mesial segments are generally planar in shape, as they are advanced into such a gap between insulation sheets.

Abstract: Ties and related methods for making insulating composite wall structures including first and second structural layers comprising a hardenable material and an insulating layer having a high thermal resistance disposed between the structural layers. The insulating layer is formed from a plurality of insulating sheets, where the sheets are sandwiched between the structural layers of the wall. During wall construction, the tie is configured to be advanced into the first structural layer before it has hardened, with the tie fitting between adjacent sheets of insulation. No pre-drilling of holes through the sheets, or screwing or pressing of the ties through the actual sheets is required. Each tie includes generally planar features to accommodate such placement, with a penetrating segment, an impact segment, and a mesial segment therebetween. At least the penetrating and mesial segments are generally planar in shape, as they are advanced into such a gap between insulation sheets.

Abstract: Ties, and related methods, for use in making insulating composite wall structures including first and second structural layers comprising a hardenable material and an insulating layer having a high thermal resistance disposed between the structural layers. The tie includes features that allow it to readily be either axially pushed through the insulating layer (e.g., by hand), or screwed through the insulating layer, (e.g., using a powered tool such as a drill). Thus, a tie of a single configuration is provided which is suitable for both methods of installation. The tie may include discontinuous helical ribs including limited prominence so as to not interfere with the ability to axially push the tie into the insulating layer by hand, yet, the ribs are prominent enough to catch the insulating layer as the tie is drilled in, helping it to “screw” into the insulating layer.

Abstract: Ties, and related methods, for use in making insulating composite wall structures including first and second structural layers comprising a hardenable material and an insulating layer having a high thermal resistance disposed between the structural layers. The tie includes features that allow it to readily be either axially pushed through the insulating layer (e.g., by hand), or screwed through the insulating layer, (e.g., using a powered tool such as a drill). Thus, a tie of a single configuration is provided which is suitable for both methods of installation. The tie may include discontinuous helical ribs including limited prominence so as to not interfere with the ability to axially push the tie into the insulating layer by hand, yet, the ribs are prominent enough to catch the insulating layer as the tie is drilled in, helping it to “screw” into the insulating layer.

Abstract: Connectors configured for providing composite wall structures with high composite action. In one embodiment, the connectors comprise a body having two spaced-apart sidewalls and a web portion extending therebetween, having a thickness that is less than the diameter or width of the sidewalls in the same dimension. The body also includes a tapered end comprising a single elongate edge or a plurality of spaced-apart edges or pointed ends at one end for facilitating penetration of the connector through layers of the composite wall during manufacture. An orienting protrusion orients the connector at a predetermined depth within the layers of the composite wall during manufacture. One or more structures anchoring anchor the connectors of the invention to layers of structural material placed on opposing sides of an insulation layer of the composite wall.

Abstract: An elongate sleeve tie is used with casting form ties in the manufacture of composite wall structures. The casting form ties and sleeve ties act to secure one or more casting forms in a rigid position relative to an insulating layer positioned between the casting forms during the manufacture of composite wall structures. The casting form tie is received in a central recess of the elongate sleeve tie. Once the composite wall has been formed, the casting form ties may be pulled out of the wall, leaving the elongate sleeve ties in place. Removal of the casting form ties eliminates the thermal bridges that metal casting form ties would otherwise create. At least a portion of the sleeve tie is formed of a material having a high thermal resistance.

Abstract: An elongate sleeve tie is used with casting form ties in the manufacture of composite wall structures. The casting form ties and sleeve ties act to secure one or more casting forms in a rigid position relative to an insulating layer positioned between the casting forms during the manufacture of composite wall structures. The casting form tie is received in a central recess of the elongate sleeve tie. Once the composite wall has been formed, the casting form ties may be pulled out of the wall, leaving the elongate sleeve ties in place. Removal of the casting form ties eliminates the thermal bridges that metal casting form ties would otherwise create. At least a portion of the sleeve tie is formed of a material having a high thermal resistance.

Abstract: Connectors configured for providing composite wall structures with high composite action. In one embodiment, the connectors comprise a body having two spaced-apart sidewalls and a web portion extending therebetween, having a thickness that is less than the diameter or width of the sidewalls in the same dimension. The body also includes a tapered end comprising a single elongate edge or a plurality of spaced-apart edges or pointed ends at one end for facilitating penetration of the connector through layers of the composite wall during manufacture. An orienting protrusion orients the connector at a predetermined depth within the layers of the composite wall during manufacture. One or more structures anchoring anchor the connectors of the invention to layers of structural material placed on opposing sides of an insulation layer of the composite wall.

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.

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.

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.