High strength composite wall connectors having a tapered edge

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.

What is claimed is:  
     
         1 . A connector for use in making an insulating composite wall structure, the connector comprising a body having a penetrating segment configured to reside within a first structural layer, a trailing segment configured to reside within a second structural layer, and a mesial segment between the penetration and trailing segments configured to reside within an insulating layer when the connector is in use, the body comprising: 
 two sidewalls;    a web portion extending between the two sidewalls;    a tapered end configured to facilitate penetration of the connector through an insulating layer and a layer of unhardened structural material adjacent to the insulating layer;    orienting means for limiting penetration of the connector through an insulating layer at a predetermined depth; and    anchoring means for anchoring at least one of the penetrating and trailing segments within a corresponding layer of hardened structural material.    
     
     
         2 . A connection as recited in  claim 1 , the sidewalls and the web portion having a substantially I-shaped cross section within the mesial segment.  
     
     
         3 . A connector is recited in  claim 1 , the sidewalls being substantially parallel and the web portion being substantially perpendicular to the sidewalls.  
     
     
         4 . A connector is recited in  claim 1 , the sidewalls having a width that is at least 50% greater than the thickness of the web portion.  
     
     
         5 . A connector is recited in  claim 1 , the sidewalls having a width that is at least twice the thickness of the web portion.  
     
     
         6 . A connector is recited in  claim 1 , the sidewalls having a width that is at least three times the thickness of the web portion.  
     
     
         7 . A connector as recited in  claim 1 , the orienting means comprising at least one protrusion extending away from the web portion at or near where the mesial and trailing segments intersect.  
     
     
         8 . A connector as recited in  claim 1 , the body comprising at least one of a cured resinous material or a thermoplastic material.  
     
     
         9 . A connector as recited in  claim 8 , the body further comprising fibers within the cured resinous or thermoplastic material.  
     
     
         10 . A connector as recited in  claim 1 , the anchoring means comprising at least one of a recess, a hole, a ridge, a protrusion, a flange, a depression, a notch, an extension, or other irregularity disposed on or within the body.  
     
     
         11 . A connector as recited in  claim 1 , at least one of the sidewalls comprising an angled face at or near the tapered end.  
     
     
         12 . A connector as recited in  claim 1 , at least one of the sidewalls terminating with a chisel-like edge at or near the vicinity of the tapered end.  
     
     
         13 . A connector as recited in  claim 1 , the tapered end terminating at a substantially straight edge.  
     
     
         14 . A connector as recited in  claim 1 , the tapered end terminating at a curved edge.  
     
     
         15 . A connector as recited in  claim 1 , the tapered end terminating at a substantially sharp edge.  
     
     
         16 . A connector as recited in  claim 1 , the tapered end terminating at a substantially blunt edge.  
     
     
         17 . A connector as recited in  claim 1 , the body further comprising a trailing wall extending at least partially between the sidewalls at an end of said body within the trailing segment.  
     
     
         18 . A connector as recited in  claim 1 , the connector being sized and configured so as to provide from about 50% to 100% composite action within an insulating composite wall structure.  
     
     
         19 . A connector as recited in  claim 1 , the connector being sized and configured so as to provide at least about 60% composite action within an insulating composite wall structure.  
     
     
         20 . A connector as recited in  claim 1 , the connector being sized and configured so as to provide at least about 70% composite action within an insulating composite wall structure.  
     
     
         21 . A connector as recited in  claim 1 , the connector being sized and configured so as to provide at least about 80% composite action within an insulating composite wall structure.  
     
     
         22 . A connector as recited in  claim 1 , the connector being sized and configured so as to provide at least about 90% composite action within an insulating composite wall structure.  
     
     
         23 . A connector for use in making an insulating composite wall structure, the connector comprising a body having a penetrating segment configured to reside within a first structural layer, a trailing segment configured to reside within a second structural layer, and a mesial segment between the penetration and trailing segments configured to reside within an insulating layer when the connector is in use, the body comprising: 
 two sidewalls;    a web portion extending between the two sidewalls;    a tapered end configured to facilitate penetration of the connector through an insulating layer and a layer of unhardened structural material adjacent to the insulating layer;    at least one protrusion extending laterally from the web portion at or near where the mesial and trailing segments intersect;    at least one of a recess, hole, ridge, protrusion, flange, depression, notch, or extension within the penetrating segment; and    at least one of a recess, hole, ridge, protrusion, flange, depression, notch, or extension within the trailing segment.    
     
     
         24 . A connector as recited in  claim 23 , the body further comprising a trailing wall extending at least partially between the sidewalls at an end of said body within the trailing segment.  
     
     
         25 . A method of manufacturing a composite wall structure, comprising: 
 providing at least one connector as recited in  claim 1;     placing an insulating layer adjacent to a first layer of unhardened structural material;    inserting the at connector through an exposed side of the insulating layer so that the mesial segment resides within the insulating layer and the penetrating segment resides within the first layer of unhardened structural material;    placing a second layer of unhardened structural material adjacent to the exposed side of the insulating layer in order for the trailing segment of the connector to reside within the second layer of unhardened structural material; and    allowing the first and second layers of unhardened structural material to harden.    
     
     
         26 . A connector as recited in  claim 25 , first and second layers of unhardened structural material hardening substantially simultaneously.  
     
     
         27 . A connector as recited in  claim 25 , first and second layers of unhardened structural material hardening sequentially.  
     
     
         28 . A method of manufacturing a composite wall structure, comprising: 
 providing at least one connector as recited in  claim 23;     placing an insulating layer adjacent to a first layer of unhardened structural material;    inserting the at connector through an exposed side of the insulating layer so that the mesial segment resides within the insulating layer and the penetrating segment resides within the first layer of unhardened structural material;    placing a second layer of unhardened structural material adjacent to the exposed side of the insulating layer in order for the trailing segment of the connector to reside within the second layer of unhardened structural material; and    allowing the first and second layers of unhardened structural material to harden.    
     
     
         29 . A connector as recited in  claim 28 , first and second layers of unhardened structural material hardening substantially simultaneously.  
     
     
         30 . A connector as recited in  claim 28 , first and second layers of unhardened structural material hardening sequentially.