US 10,870,988 B2 · Tie for composite wall system fitting 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.

Claims21

Dependent claims

A tie for use in making an insulating composite wall structure including first and second structural layers comprising hardenable material and an insulating layer having a high thermal resistance disposed between the first and second structural layers, the tie comprising:

a body including first and second shaft bodies, each shaft body including a penetrating segment, an impact segment, and a mesial segment extending therebetween, such that the body includes a pair of penetrating segments, a pair of impact segments, and a pair of mesial segments, wherein the pair of mesial segments are joined together by a bridging web that bridges between the first and second shaft bodies;
a pointed tip at an end of each of the penetrating segments configured to penetrate between adjacent sheets of the insulating layer;
wherein at least the penetrating segments, the mesial segments, and the bridging web of the tie are generally planar, each having a maximum thickness that is no more than 0.4 inch, so as to fit between adjacent sheets of the insulating layer.

a body including left and right shaft body portions, the left and right shaft body portions each including a penetrating segment, an impact segment, and a mesial segment extending therebetween, such that the body includes a right penetrating segment, a right impact segment, a right mesial segment, a left penetrating segment, a left impact segment, and a left mesial segment wherein the left and right shaft body portions are joined together by a bridging web that bridges between the left and right shaft body portions;
a pointed tip confined to the same plane as a plane defining the mesial and penetrating segments, at an end of each of the penetrating segments, configured to penetrate between adjacent sheets of the insulating layer;
wherein at least the penetrating segments, the mesial segments, and the bridging web of the tie are generally planar, each having a maximum thickness that is no more than 0.4 inch, so as to fit between adjacent sheets of the insulating layer.

A method for manufacturing an insulating composite wall structure including first and second structural layers and an insulating layer disposed between the first and second structural layers in a desired configuration, the method comprising:

providing a tie comprising:
a body including first and second shaft bodies, each shaft body including a penetrating segment, an impact segment, and a mesial segment extending therebetween, such that the body includes a pair of penetrating segments, a pair of impact segments, and a pair of mesial segments, wherein the pair of mesial segments are joined together by a bridging web that bridges between the first and second shaft bodies;
a pointed tip at an end of each of the penetrating segments for penetrating between adjacent sheets of the insulating layer;
wherein at least the penetrating segments, the mesial segments, and the bridging web of the tie are generally planar, each having a maximum thickness that is no more than 0.4 inch, so as to fit between adjacent sheets of the insulating layer;
forming the first structural layer from a hardenable high strength structural material;
positioning an insulating layer comprising a material having a higher thermal resistance than the first structural layer against a surface of the first structural layer while the first structural layer is in a substantially unhardened state;
advancing one or more of the ties between adjacent sheets of the insulating layer so that the ties do not substantially penetrate the sheets of the insulating layer;
wherein the penetrating segments of each tie penetrate and are embedded within the first structural layer, such that the mesial segment is disposed substantially between adjacent sheets of the insulating layer, and such that a substantial portion of each impact segment extends outwardly from between sheets of the insulating layer;
forming the second structural layer from a hardenable high strength structural material on an exposed surface of the insulating layer such that the substantial portion of the impact segment extending from between the sheets of the insulating layer is embedded within the second structural layer;
and
allowing the first and second structural layers to become substantially hardened, thereby forming the insulating composite wall structure in which the first structural layer, and the second structural layer are secured together by the one or more ties.

8 more elements

Dependencies are inferred from the claim text.

Tie for composite wall system fitting between insulation sheets

Life of this patent

Tie for composite wall system fitting between insulation sheets

Life of this patent

Abstract

Claims21