US 5,519,973 AGranted

Highly insulative connector rods and methods for their manufacture and use in highly insulated composite walls

AssigneeH.K. Composites, Inc.

InventorsDavid O. Keith, David M. Hansen

Life of this patent

Estimating the term…

Loading patent…

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.

Claims13

Dependent claims

A connector rod used in making an insulating composite wall structure including first and second structural layers comprising a hardenable material and an insulating layer having a high thermal resistance disposed between the first and second structural layers, said connector rod comprising a cured resinous or plastic material having a high thermal resistance, said connector rod including:

an elongate shaft having a penetrating segment, an impact segment, and a mesial segment therebetween;
a substantially pointed tip at an end of said penetrating segment distal to said mesial segment for penetrating the insulating layer and the first structural layer while yet in an unhardened state;
an enlarged head at an end of said impact segment distal to said mesial segment, said enlarged head being embedded within the second structural layer when used in making the composite wall structure;
means for orienting said connector rod within the insulating layer at a predetermined depth;
means within said penetrating segment for anchoring said penetrating segment within the first structural layer when substantially hardened;
and
means within said impact segment for anchoring said impact segment within the second structural layer when substantially hardened,
said connector layer having a strength and configuration such that when used in the manufacture of a composite wall structure in which the insulating layer is disposed between the first and second structural layers in a desired configuration said connector rod will remain firmly embedded within the structural layers while substantially retaining the structural layers and insulating layer in the desired configuration, said connector rod having a configuration such that when said connector rod is embedded within the composite wall structure said orienting means does not completely penetrate the insulating layer.

5 more elements

A highly insulating composite wall structure including:

(1) a first structural layer comprising a hardenable high strength material;
(2) a second structural layer comprising a hardenable high strength material;
(3) a highly insulating layer comprising a material having a high thermal resistance, said insulating layer being disposed between said first and second structural layers in a desired configuration, said first structural layer, said second structural layer, and said insulating layer being secured together by means of a connector rod comprising a material having a high thermal resistance and including:
(a) an elongate shaft having
(i) a penetrating segment embedded substantially within said first structural layer;
(ii) an impact segment embedded substantially within said second structural layer;
and
(iii) a mesial segment disposed substantially within said insulating layer;
(b) a substantially pointed tip at an end of said penetrating segment distal to said mesial segment for penetrating the insulating layer and the first structural layer while yet in a substantially unhardened state;
(c) an enlarged head at an end of said impact segment distal to said mesial segment, said enlarged head being embedded within the second structural layer;
(d) means for orienting said connector rod within said insulating layer at predetermined depth;
(e) means within said penetrating segment for anchoring said penetrating segment within said first structural layer when substantially hardened;
and
(f) means within said impact segment for anchoring said impact segment within said second structural layer when substantially hardened,
said connector rod having a strength and configuration such that said connector rod will remain firmly embedded within said structural layers while substantially retaining said structural layers and insulating layer in the desired configuration, said connector rod having a configuration such that said orienting means does not completely penetrate said insulating layer.

12 more elements

Dependencies are inferred from the claim text.

Facts

Application: 08/225,910Filed 8 Apr 1994 · continuation in part
Priority: 17 Aug 1993
Granted: 28 May 1996
Term ends: Not estimatedThe source records don’t support an estimate.

Classification34 codes

B32B 7/08
Interconnection of layers: by mechanical means
B28B 19/003
Machines or methods for applying the material to surfaces to form a permanent layer thereon: to insulating material
B29C 37/0082
Measures or configurations for obtaining anchoring effects in the contact areas between layers: mechanical anchoring
B32B 5/18
Layered products characterised by the non- homogeneity or physical structure , i.e. comprising a fibrous, filamentary, particulate or foam…