Multi-prong connectors used in making highly insulated composite wall structures

A multi-prong connector used in making a composite wall structure which includes first and second structural layers comprising a hardenable material and an insulating layer disposed between the first and second structural layers, wherein the connector comprises an insulating material and includes:

• (a) a gripping segment having a bridging structure;
• (b) a plurality of elongate prongs attached together by and extending from the bridging structure in a substantially parallel orientation, each prong having a penetrating segment distal to the bridging structure and a mesial segment disposed between the penetrating segment and the gripping segment;
• (c) a substantially pointed tip disposed on an end of each of the prongs;
• (d) at least one recess disposed within the penetrating segment of each of the prongs for anchoring the connector within the first structural layer when substantially hardened;
• (e) second anchoring means within the gripping segment for anchoring the connector within the second structural layer when substantially hardened;
• and
• (f) abutment means for limiting penetration of the connector through the insulating layer during placement of the connector.

An insulating composite wall structure comprising first and second structural layers made from a hardenable material and an insulating layer disposed between the first and second structural layers, the first and second structural layers and the insulating layer being secured together by means of a plurality of multi-prong connectors comprising an insulating material and including:

• (a) a gripping segment having a bridging structure;
• (b) a plurality of elongate prongs attached together by and extending from the bridging structure, each prong having a penetrating segment distal to the bridging structure and a mesial segment disposed between the penetrating segment and the gripping segment;
• (c) a penetrating tip disposed on an end of at least one of the prongs and having a reduced cross-section width relative to the rest of the prong;
• (d) first anchoring means disposed within the penetrating segment of at least one of the prongs for anchoring the connector within the first structural layer when substantially hardened;
• and
• (e) second anchoring means within the gripping segment for anchoring the connector within the second structural layer when substantially hardened.