Insulating connectors for securing insulation to an existing structure

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.

What is claimed is:  
     
         1 . A connector for use in connecting an insulating layer to a structural layer, the connector comprising: 
 a body;    an enlarged contact surface disposed on the body, the enlarged contact surface being configured to engage a surface of an insulating layer;    separating means for separating the enlarged contact surface from a structural layer by a predetermined distance, wherein the separating means is configured to pass at least partially through the insulating layer and to engage the structural layer, the separating means protruding away from the enlarged contact surface; and    interconnecting means for attaching a tie or wire of an outer wall layer to the connector,    wherein at least the separating means is composed of a thermally insulating material.    
     
     
         2 . A connector as recited in  claim 1 , wherein the enlarged contact surface is planar.  
     
     
         3 . A connector as recited in  claim 1 , wherein the separating means includes a stem that protrudes away from the enlarged contact surface.  
     
     
         4 . A connector as recited in  claim 3 , wherein the stem is configured to threadably engage the insulating layer.  
     
     
         5 . A connector as recited in  claim 3 , wherein the stem is hollow.  
     
     
         6 . A connector as recited in  claim 3 , wherein the connector further includes a coupling means for coupling the connector with the structural layer.  
     
     
         7 . A connector as recited in  claim 6 , wherein the coupling means includes at least one of a screw and a bolt that is disposed within the stem when coupling the connector with the structural layer.  
     
     
         8 . A connector as recited in  claim 6 , wherein the coupling means includes an embed that is configured to be mounted to the structural layer.  
     
     
         9 . A connector as recited in  claim 8 , wherein the embed includes anchoring means for anchoring the embed within the structural layer.  
     
     
         10 . A connector as recited in  claim 9 , wherein the anchoring means includes at least one of a ridge and a taper that is configured to anchor the embed within the structural layer.  
     
     
         11 . A connector as recited in  claim 8 , wherein the embed is configured to engage the stem of the connector with a bayonet-type connection, and wherein the embed is configured to be inserted at least partially within a hollow portion of the embed and to be rotated within the hollow portion of the embed.  
     
     
         12 . A connector as recited in  claim 8 , wherein the embed is configured to engage the stem of the connector with a snap-fit type connection, and wherein the stem of the connector includes a tip that is configured to snap into a hollow portion of the embed.  
     
     
         13 . A connector as recited in  claim 8 , wherein the embed includes structures protruding away from the embed that are configured to slidably engage a flat concrete tie.  
     
     
         14 . A connector as recited in  claim 1 , further including a sealing means for helping to seal the enlarged contact surface with the insulating layer.  
     
     
         15 . A connector as recited in  claim 14 , wherein the sealing means includes a rubber washer.  
     
     
         16 . A connector as recited in  claim 14 , wherein the sealing means includes a raised surface that protrudes away from the enlarged contact surface.  
     
     
         17 . A connector as recited in  claim 3 , where in the means for separating includes at least two stems that protrude away from the enlarged contact surface.  
     
     
         18 . A connector as recited in  claim 17 , wherein each stem is configured to engage the structural layer when the enlarged contact surface is engaged with the insulating layer so as to prevent the enlarged contact surface from passing towards the structural layer beyond the predetermined distance.  
     
     
         19 . A connector as recited in  claim 1 , wherein the interconnecting means includes mounting structure that protrudes away from the connector.  
     
     
         20 . A connector as recited in  claim 19 , wherein the mounting structure is configured to engage a brick tie wire.  
     
     
         21 . A connector as recited in  claim 19 , wherein the mounting structure is configured to engage a wire mesh.  
     
     
         22 . A connector as recited in  claim 1 , wherein the thermally insulating material includes a material that is selected from the group of polyphenylsulfones resins, polypthalamides, polyamides, polyarylsulfones, polycarbonates, polysulfones, polyphthenyl sulfones, polyether sulfones, aliphatic polyketones, acrylics, nylons and polyesters.  
     
     
         23 . A connector as recited in  claim 22 , wherein the thermally insulating material is combined with at least one of high strength resin, a fiber and a filler.  
     
     
         24 . A connector for use in connecting an insulating layer to a structural layer, the connector comprising: 
 a body,    an enlarged contact surface disposed on the body, the enlarged contact surface being configured to conform to the shape of an insulating layer; and    a plurality of hollow stems protruding away from the enlarged contact surface, the stems being composed of a thermally insulating material and being configured to engage the structural layer when the enlarged contact surface is disposed a predetermined distance away from the structural layer; and    at least one screw disposed within at least one of the hollow stems, the at least one screw being configured to secure the connector to the structural layer.    
     
     
         25 . A connector as recited in  claim 24 , wherein said at least one screw is self-tapping.  
     
     
         26 . A connector as recited in  claim 24 , wherein each of the plurality of hollow stems includes a screw disposed therein.  
     
     
         27 . A connector as recited in  claim 24 , wherein each of hollow stems further includes a sealing means disposed thereabout for sealing the enlarged contact surface with the insulating layer.  
     
     
         28 . A connector as recited in  claim 27 , wherein said sealing means includes a raised surface about each hollow stem.  
     
     
         29 . A connector as recited in  claim 27 , wherein said sealing means includes a rubber gasket disposed about each hollow stem.  
     
     
         30 . A connector as recited in  claim 24 , further including mounting structure that protrudes away from the connector and that is configured to connect to a tie or wire.  
     
     
         31 . A connector as recited in  claim 30 , wherein said tie or wire is connected to an outer layer comprising one of a stucco wall and a brick wall.  
     
     
         32 . A connector as recited in  claim 30 , wherein said enlarged contact surface is flat.  
     
     
         33 . A connector as recited in  claim 24 , wherein the thermally insulating material includes a material that is selected from the group of polyphenylsulfones resins, polypthalamides, polyamides, polyarylsulfones, polycarbonates, polysulfones, polyphthenyl sulfones, polyether sulfones, aliphatic polyketones, acrylics, nylons and polyesters.  
     
     
         34 . A connector for use in connecting an insulating layer and a structural layer, the connector comprising: 
 a body;    an enlarged contact surface disposed on the body, the enlarged contact surface being configured to engage a surface of an insulating layer;    a stem protruding away from the enlarged contact surface, the stem being composed of a thermal insulating material and being configured to engage a structural layer; and    mounting structure protruding away from the connector that is configured to connect an outer layer to the composite wall.    
     
     
         35 . A connector as recited in  claim 34 , wherein the stem is threaded.  
     
     
         36 . A connector as recited in  claim 35 , wherein the stem is self-tapping.  
     
     
         37 . A connector as recited in  claim 34 , wherein the stem is configured to couple with an embed that is mounted within the structural layer.  
     
     
         38 . A connector as recited in  claim 37 , wherein the stem is configured to couple with the embed in a bayonet-type connection.  
     
     
         39 . A connector as recited in  claim 37 , wherein the stem is configured to couple with the embed in a snap-fit connection.  
     
     
         40 . A connector as recited in  claim 37 , wherein the stem is configured to couple with a threaded coupling.  
     
     
         41 . A connector as recited in  claim 34 , wherein the mounting structure is configured to engage a wire mesh of a stucco wall.  
     
     
         42 . A connector as recited in  claim 34 , wherein the mounting structure is configured to engage a brick tie wire.  
     
     
         43 . A connector as recited in  claim 34 , wherein the thermally insulating material includes a material that is selected from the group of polyphenylsulfones resins, polypthalamides, polyamides, polyarylsulfones, polycarbonates, polysulfones, polyphthenyl sulfones, polyether sulfones, aliphatic polyketones, acrylics, nylons and polyesters.  
     
     
         44 . An embed for use in connecting an insulating layer to a structural layer wall, the embed comprising: 
 a hollow body configured to be mounted within a structural layer, the hollow body being configured to receivably engage the stem of a connector; and    wing structures protruding away from the hollow body, the wing structures being configured to slidably engage a flat strap.    
     
     
         45 . An embed as recited in  claim 44 , wherein the embed is configured to engage a connector for use in connecting an insulating layer and a structural layer, the connector including: 
 a body;    an enlarged contact surface disposed on the body, the enlarged contact surface being configured to engage a surface of the insulating layer;    at least one stem configured to separate the enlarged contact surface from the structural layer by a predetermined distance, wherein the at least one stem is configured to pass at least partially through the insulating layer and to engage the structural layer.    
     
     
         46 . An embed as recited in  claim 45 , wherein the embed is configured to engage the connector with a bayonet-type coupling.  
     
     
         47 . An embed as recited in  claim 45 , wherein the embed is configured to engage the connector with a snap-fit coupling.  
     
     
         48 . An embed as recited in  claim 45 , wherein the embed is configured to engage the connector with a threaded coupling.  
     
     
         49 . An embed as recited in  claim 44 , further including anchoring means for anchoring the embed within the structural layer when the structural layer is in a hardened state.  
     
     
         50 . An embed as recited in  claim 49 , wherein the anchoring means includes a ridge circumferentially extending around the embed.  
     
     
         51 . An embed as recited in  claim 44 , wherein the embed is composed of a thermally insulating material that is selected from the group of polyphenylsulfones resins, polypthalamides, polyamides, polyarylsulfones, polycarbonates, polysulfones, polyphthenyl sulfones, polyether sulfones, aliphatic polyketones, acrylics, nylons and polyesters.