Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
TIE SYSTEM FOR INSULATED CONCRETE PANELS
[0001]
FIELD OF THE INVENTION
[0002] Embodiments of the present invention are direct generally to a new tie
system and method for making insulated concrete panels. More specifically,
embodiments of the present invention are directed to using the new tie system
to more
effectively and efficiently manufacture improved insulated concrete panels.
BACKGROUND OF THE INVENTION
[0003] Insulated concrete panels are well known in the construction industry.
Such
concrete panels are generally formed with insulation layers sandwiched between
top and
bottom concrete layers. To secure the concrete layers to the insulation
layers, connectors
(otherwise known as "ties") may be used. The ties will connect the two
concrete layers
together through the insulation layer. As such, the ties hold the components
of the
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insulated concrete panels together and also provide a mechanism whereby loads
can be
transferred between the concrete layers.
[0004] Depending on the application, the ties may be formed in various shapes
and from various materials. In the past, metals, such as iron or steel, have
been used to
form such ties. However, metals are high thermal conductors and, as such,
permit
undesirable thermal conduction through the concrete layers. Furthermore, the
insulation
layer that receives such ties will usually be formed with holes for receiving
the ties. Often,
such holes are formed much larger than the ties themselves. Such a mismatch
between
the size of the ties and the holes further decreases the thermal efficiency of
the concrete
wall panels.
[0005] Based on design considerations, the size (e.g., the thickness) of the
insulation layers used in the insulated concrete panels may vary widely. For
example,
construction of a single building may require a plurality of different types
of insulated
concrete panels to be used, with each panel having a different insulation
layer size. In
more detail, a building may require that its exterior walls be constructed
from insulated
concrete panels having a very thick insulation layer, so as to reduce heat
transfer to/from
the ambient. Contrastingly, the building may have interior walls that are
required to be
constructed from insulated concrete panels having an insulation layer with a
reduced
thickness. Such an insulation layer with a reduced thickness may be used
because the
interior walls may not need to restrict heat transfer as much as the exterior
walls.
However, incorporating insulated concrete panels with insulation layers having
varying
sizes necessarily requires the use of ties of varying sizes. Specifically,
thicker insulation
layers require the use of larger ties, while thinner insulation layers require
the use of
smaller ties. The need to use varying sizes of ties can increase the
complexity and
decrease the efficiency of construction processes in building projects.
[0006] Accordingly, there is a need in the industry for a tie for an insulated
concrete
panel that provides the necessary strength for building applications, while at
the same
time, provides enhanced thermal insulation. Furthermore, there is a need for a
single tie
that is capable of being used with insulated concrete panels having insulation
layers of
various sizes.
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SUMMARY OF THE INVENTION
[0007] In one embodiment of the present invention, there is provided an
insulated
concrete panel. The panel comprises an insulation layer having one or more
openings
extending therethrough, a first concrete layer adjacent to a first surface of
the insulation
layer, a second concrete layer adjacent to a second surface of the insulation
layer, and a
wall tie received within one of the openings in the insulation layer. The wall
tie includes a
central section received within one of the openings of the insulation layer
and a first
concrete engaging section comprised of first and second protrusion portions at
least
partially embedded within the first concrete layer. The first concrete
engaging section
extends from a first end of the central section. The wall tie further includes
a second
concrete engaging section comprising first and second end portions embedded
within the
second concrete layer. The second concrete engaging section extends from a
second
end of the central section. The second concrete engaging section has a maximum
width
that is larger than a maximum width of the central section. The central
section of the wall
tie is configured to transfer shear forces and resist delamination forces
between the first
and second concrete layers.
[0008] In another embodiment of the present invention, there is provided a
method
of making an insulated concrete panel. The method comprising the initial step
of forming
one or more tie openings through an insulation layer, with such insulation
layer including
a first surface and a second surface. An additional step includes inserting a
wall tie into
each of the tie openings, with each wall tie comprising first and second
concrete engaging
sections opposing a central section. The second concrete engaging section has
a
maximum width that is larger than a maximum width of the central section. An
additional
step includes pouring a first layer of concrete. An additional step includes
placing the
insulation layer on the first layer of concrete, such that the first surface
of the insulation
layer is in contact with the first layer of concrete. During the placing of
step, the first
concrete engaging section of the wall tie is at least partially embedded
within the first
layer of concrete. An additional step includes pouring a second layer of
concrete over the
second surface of the insulation layer. During such pouring step, the second
concrete
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engaging portion of the wall tie is at least partially embedded within the
second layer of
concrete. The central section of the wall tie is configured to transfer shear
forces and
restrict delamination forces between the first and second layers of concrete.
[0009] In yet another embodiment of the present invention, there is provided a
wall
tie for use with insulated concrete panels, with the panels including first
and second
layers. The wall tie comprises a central section and a first concrete engaging
section
including first and second protrusion portions. The first concrete engaging
section extends
from a first end of the central section. The wall tie further comprises a
second concrete
engaging section including first and second end portions, with the second
concrete
engaging section extending from a second end of the central section. The
second
concrete engaging section has a maximum width that is larger than a maximum
width of
said central section, and the central section is configured to transfer shear
forces and
restrict delamination forces between the first and second layers.
[0010] This summary is provided to introduce a selection of concepts in a
simplified
form that are further described below in the detailed description. This
summary is not
intended to identify key features or essential features of the claimed subject
matter, nor
is it intended to be used to limit the scope of the claimed subject matter.
Other aspects
and advantages of the present invention will be apparent from the following
detailed
description of the embodiments and the accompanying drawing figures.
BRIEF DESCRIPTION OF THE FIGURES
[0011] Embodiments of the present invention are described herein with
reference
to the following drawing figures, wherein:
[0012] FIG. 1 is a top perspective view of a tie system in an assembled
configuration according to embodiments of the present invention;
[0013] FIG. 2 is a bottom perspective view of the tie system of FIG. 1 in the
assembled configuration;
[0014] FIG. 3 is a bottom perspective view of the tie system of FIGS. 1-2 in
the
assembled configuration and having a first structural member and a second
structural
member, with the tie system being shown in a first and second rotational
position, and
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with the second structural member being shown in dashed-line in the second
rotational
position;
[0015] FIG. 4 is a side perspective view of the tie system of FIGS. 1-3 in a
disassembled configuration;
[0016] FIG. 5 is a top perspective view of the tie system of FIGS. 1-4 in a
disassembled configuration;
[0017] FIG. 6 is a bottom perspective view of the tie system of FIGS. 1-5 in a
disassembled configuration;
[0018] FIG. 7 is an illustration of the tie system of FIGS. 1-6 in a collapsed
configuration and prepared for insertion into a tie opening of an insulation
layer;
[0019] FIG. 8 is an illustration of the tie system of FIGS. 1-6 in a collapsed
configuration and inserted into the tie opening of the insulation layer from
FIG. 7, with a
portion of the insulation layer removed at a horizontal cross-section for
clarity;
[0020] FIG. 9 is an additional illustration of the tie system of FIGS. 1-6 in
a
collapsed configuration and inserted into the tie opening of the insulation
layer from FIGS.
7-8, with a portion of the insulation layer removed at a vertical cross-
section for clarity;
[0021] FIG. 10 is an illustration of the tie system of FIGS. 1-6 in an
expanded
configuration and inserted into the tie opening of the insulation layer from
FIGS. 7-9, with
a portion of the insulation layer removed at a horizontal cross-section for
clarity;
[0022] FIG. 11 is an additional illustration of the tie system of FIGS. 1-6 in
an
expanded configuration and inserted into the tie opening of the insulation
layer from FIGS.
7-10, with a portion of the insulation layer removed at a vertical cross-
section for clarity;
[0023] FIG. 12 is an illustration of an insulated concrete panel formed from
an
insulation layer, a top layer of concrete, a bottom layer of concrete, and a
plurality of the
tie systems from FIGS. 1-6;
[0024] FIG. 13 is a flow chart illustrative of a method for making an
insulated
concrete panel according to embodiments of the present invention;
[0025] FIG. 14 is a bottom exploded view of an additional embodiment of a tie
system in a disassembled configuration according to embodiments of the present
invention, with the tie system having extension members and hubs, and with the
extension members being separable from the hubs; and
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[0026] FIG. 15 is top exploded view of the tie system of FIG. 14 in a
disassembled
configuration.
[0027] FIG. 16 is a top perspective view of a tie system according to
embodiments
of the present invention, with the tie system particularly illustrating
spherical barriers
extending from hub sections of the tie system;
[0028] FIG. 17 is a bottom perspective view of the tie system of FIG. 16;
[0029] FIG. 18 is a top exploded view of the tie system of FIGS. 16-17;
[0030] FIG. 19 is a bottom exploded view of the tie system of FIGS. 16-18;
[0031] FIG. 20 is an illustration of the tie system of FIGS. 16-19 inserted
into a tie
opening of an insulation layer, with a portion of the insulation layer removed
at a horizontal
cross-section for clarity;
[0032] FIG. 21 is an illustration of the tie system of FIGS. 16-19 inserted
into a tie
opening of an insulation layer, with a portion of the insulation layer removed
at a vertical
cross-section for clarity;
[0033] FIG. 22 is an illustration of an insulated concrete panel formed from
an
insulation layer, a top layer of concrete, a bottom layer of concrete, and a
plurality of the
tie systems from FIGS. 16-19;
[0034] FIG. 23 is a front perspective view of a tie system according to
embodiments
of the present invention, with the tie system particularly illustrating a
central section
opposed by first and second concrete engaging sections;
[0035] FIG. 24 is a top perspective view of the tie system of FIG. 23;
[0036] FIG. 25 is an illustration of the tie system of FIGS. 23-24 inserted
into a tie
opening of an insulation layer, with a portion of the insulation layer removed
at a horizontal
cross-section for clarity;
[0037] FIG. 26 is an illustration of an insulated concrete panel formed from
an
insulation layer, a top layer of concrete, a bottom layer of concrete, and a
plurality of the
tie systems from FIGS. 23-24;
[0038] FIG. 27 is a perspective view of an X-shaped tie system with a T-shaped
cross-section according to embodiments of the present invention;
[0039] FIG. 28 is a top plan view of the tie system of FIG. 27;
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[0040] FIG. 29 is a perspective view of an additional embodiment of an X-
shaped
tie system with a T-shaped cross-section, particularly illustrating the tie
system including
one or more tabs extending from a projection of the tie system;
[0041] FIG. 30 is a perspective view of a further embodiment of an X-shaped
tie
system with a T-shaped cross-section, particularly illustrating the tie system
including
teeth-like portions on a projection of the tie system;
[0042] FIG. 31 is a perspective view of an X-shaped tie system with an L-
shaped
cross-section according to embodiments of the present invention;
[0043] FIG. 32 is a perspective illustration of a stack of insulation layers,
with each
layer including a plurality of X-shaped grooves extending through a side edge
of the layer;
[0044] FIG. 33 is a perspective illustration of a hot-wire system used to form
X-
shaped grooves in insulation layers, with the hot-wire system particularly
illustrating two
planes of wires;
[0045] FIG. 34 is a perspective illustration of a single plane hot-wire system
used
to form X-shaped grooves in insulation layers, with the single plane hot-wire
system
particularly illustrating a single plane of wires;
[0046] FIG. 35 is a perspective view of tie-positioning template according to
embodiments of the present invention;
[0047] FIG. 36 is a partial perspective view of the tie-positioning template
from FIG.
35 positioned on a side edge of an insulation layer;
[0048] FIG. 37 is a partial perspective view of the insulation layer from FIG.
36,
particularly illustrating an X-shaped groove that was formed via use of the
tie-positioning
template from FIG. 35;
[0049] FIG. 38 is a partial front perspective view of an insulation layer
including a
plurality of X-shaped grooves on a side edge, and illustrating two tie systems
from FIG.
29 installed in two of the X-shaped grooves;
[0050] FIG. 39 is a partial rear perspective view of the insulation layer from
FIG. 38;
[0051] FIG. 40 is an illustration of a stack of insulation layers with tie
systems pre-
inserted on their side edges; and
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[0052] FIG. 41 is an illustration of an insulated concrete panel formed from
two
insulation layers, a top layer of concrete, a bottom layer of concrete, and a
plurality of the
tie systems from FIG. 29.
[0053] The drawing figures do not limit the present invention to the specific
embodiments disclosed and described herein. The drawings are not necessarily
to scale,
emphasis instead being placed upon clearly illustrating the principles of the
invention.
DETAILED DESCRIPTION
[0054] The following detailed description of the present invention references
various embodiments. The embodiments are intended to describe aspects of the
invention in sufficient detail to enable those skilled in the art to practice
the invention.
Other embodiments can be utilized and changes can be made without departing
from the
scope of the present invention. The following detailed description is,
therefore, not to be
taken in a limiting sense. The scope of the present invention is defined only
by the
appended claims, along with the full scope of equivalents to which such claims
are
entitled.
[0055] As will be described in more detail below, FIGS. 1-12 show an
embodiment
of the invention where structural members of a tie system are integrally
formed of a single
material having a low thermal conductivity, such as non-metallic composite
material.
Alternatively, FIGS. 14-15 show an embodiment of the invention where
structural
members of a tie system are formed of two different materials, such as a first
material
having a high thermal conductivity (e.g., steel) and a second material having
a low thermal
conductivity (e.g., a non-metallic composite material). The single-material
tie system of
FIG. 1-12 will be described first, followed by a description of the multi-
material tie system
of FIGS. 14-15.
[0056] Nevertheless, in this description, references to "one embodiment," "an
embodiment," or "embodiments" mean that the feature or features being referred
to are
included in at least one embodiment of the technology. Separate references to
"one
embodiment," "an embodiment," or "embodiments" in this description do not
necessarily
refer to the same embodiment and are also not mutually exclusive unless so
stated and/or
except as will be readily apparent to those skilled in the art from the
description. For
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example, a feature, structure, act, etc. described in one embodiment may also
be included
in other embodiments, but is not necessarily included. Thus, the present
technology can
include a variety of combinations and/or integrations of the embodiments
described
herein.
Single-Material Tie System
[0057] With reference to FIGS. 1-6, embodiments of the present invention
include
a tie system 10 for use in forming an insulated concrete panel. The tie system
10 includes
a first structural member 12 comprising a first hub 14 and a pair of first
extension members
16 coupled to said first hub 14, such that the first extension members 16
extend outwardly
from the first hub 14 in generally opposite directions. The tie system 10
further includes
a second structural member 18 comprising a second hub 20 and a pair of second
extension members 22 coupled to the second hub 20, such that the second
extension
members 22 extend outwardly from the second hub 20 in generally opposite
directions.
The first and second hubs 14, 20 are configured to be rotatably coupled to one
other
(when coupled together the hubs 14, 20 may define a hub portion) in a manner
that
permits rotation of the first and second structural members 12, 18 relative to
one another
about an axis of rotation 23 (See FIGS. 1-2) extending through the first and
second hubs
14,20. In more detail, as illustrated by FIGS. 4-6, the hub 14 of the first
structural member
12 may be equipped with a hub projection 24, and the hub 20 of the second
structural
member 18 may be equipped with a hub recess 26. Embodiments provide for the
hub
projection 24 to be received within the hub recess 26 so as to rotatably
couple the first
and second structural members 12, 18 together. Such a configuration provides
for the tie
system 10 to be capable of shifting between a collapsed configuration and an
expanded
configuration (as will be discussed in more detail below) by rotating the
first and second
structural members 12, 18 relative to one another about the axis of rotation
23.
[0058] The tie system 10, as described above, is further operable to be
configured
in an assembled and disassembled configuration. In FIGS. 1-3, the tie system
10 is shown
in the assembled configuration, where the first and second structural members
12, 18 are
rotatably coupled to one another in a scissor-like configuration. As
illustrated in FIG. 3,
when the tie system 10 is assembled, the first and second structural members
12, 18 can
rotate relative to one another on an axis of rotation that extends through the
coupled first
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and second hubs 14, 20. This manner of rotatably coupling the first and second
structural
members 12, 18 gives the tie system 10 the scissor-like configuration. As used
herein,
the term "scissor-like configuration" means a configuration of two elongated
components,
where the elongated components are rotatably coupled to one another at a
connection
location that is spaced from ends of both the elongated components, so that
expansion
or contraction of the ends of the components on one side of the connection
location
causes corresponding expansion or contraction of the ends of the components on
the
other side of the connection location. FIGS. 4-6 show the tie system 10 in a
disassembled
configuration, where the first and second structural members 12, 18 are not
coupled to
one another.
[0059] As illustrated in the drawings, certain embodiments provide for the
first and
second structural members 12, 18 to each have substantially the same shape.
Furthermore, each of the first and second structural members 12, 18 may be
substantially
symmetrical about the axis of rotation 23. In some embodiments, the first and
second
structural members 12, 18 may each have a length of between 3 to 18 inches,
between
4 to 15 inches, between 5 to 12 inches, or between 6 to 9 inches.
Additionally, in some
embodiments, the first and second structural members 12, 18 may each have a
width of
between 1 to 6 inches, between 2 to 5 inches, or between 3 to 4 inches.
Finally, in some
embodiments the hubs 14, 20 will have a width (e.g., an outer diameter) of
between 1 to
12 inches, between 2 to 6 inches, between 2.5 to 4 inches, or between 2.75 to
3.25
inches.
[0060] As best illustrated in FIG. 4, each of the first and second structural
members
12, 18 of the tie system 10 presents an inwardly-facing side 30 and an
outwardly-facing
side 32, with the inwardly and outwardly-facing sides 30, 32 of each
structural member
12, 18 facing an opposite direction. In the assembled configuration of FIGS. 1-
3, such as
when said first and second hubs 14, 20 are rotatably coupled to one another,
the inwardly-
facing sides 30 of the first and second structural members 12, 18 engage one
another.
[0061] Returning to FIGS. 4-6, the hub 14 of the first structural member 12
may be
formed with the hub projection 24 and the hub 20 of the second structural
member 18
may be formed with the hub recess 26. The hub projection 24 may extend from a
portion
of the inwardly-facing side 30 of the first structural member 12. In some
embodiments,
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the hub projection 24 may form at least a portion of the inwardly-facing side
30 of the first
structural member 12. Contrastingly, the hub recess 26 penetrates within the
second hub
20 from the inwardly-facing side 30 of the second structural member 18. In
some
embodiments, the hub recess 26 extends through an entire width of the second
hub 20,
such that the hub recess 26 presents an opening through the second hub 20.
Embodiments provide for the hub projection 24 and the hub recess 26 to be
complementary sized, such that the hub projection 24 can be received within
the hub
recess 26 in the assembled configuration, such as shown in FIGS. 1-3. For
example, in
some embodiments, the hub projection 24 has a cross-sectional area of 0.1,
0.25, 0.5,
0.75, 1, or more square inches. Similarly, the hub recess 26 may present a
cross-sectional
open area of at least 0.1, 0.25, 0.5, 0.75, 1, or more square inches. As such,
the tie system
can be assembled by inserting the hub projection 24 into the hub recess 26. In
such
an assembled configuration, the receipt of the hub projection 24 in the hub
recess 26
inhibits translation of the first and second structural members 12, 18, while
permitting
rotation of the first and second structural members 12, 18 relative to one
another on the
axis of rotation 23.
[0062] As best illustrated in FIGS. 4-6, embodiments of the present invention
further provide for each of the first and second structural members 12, 18 to
include a
plurality of radially-extending ribs 34 extending about at least a portion of
the inwardly-
facing sides 30 of the members' hubs 14, 20. With particular reference to FIG.
4, each of
the ribs 34 is separated by a gap 36. In the assembled configuration, such as
when said
first and second hubs 14, 20 are rotatably coupled to one another, the ribs 34
of the first
structural member 12 are configured to engage within the gaps 36 of the second
structural
member 18, and the ribs 34 of the second structural member 18 are configured
to engage
within the gaps 36 of the first structural member 12. As such, the ribs 34 and
gaps 36 are
configured engage with each other so as to hold the first and second
structural members
12, 18 relative to one another in a plurality of different rotational
positions. As such, the
first and second structural members 12, 18 may be "locked" in various relative
rotational
positions. Such a configuration provides for a single tie system 10 to be used
with
insulation layers of varying sizes (e.g., varying thicknesses). It is
understood that a greater
number of ribs 34 facilitates the first and second structural members 12, 18
to be held in
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a correspondingly greater number of different rotational positions. Certain
embodiments
may provide for each of the first and second structural members 12, 18 to
include between
and 200 ribs 34, between 20 and 100 ribs 34, or between 40 and 60 ribs 34. As
will be
discussed in more detail below, in addition to the ribs 34 and gaps 36,
certain
embodiments will provide for the first and second structural members 12, 18 to
be held in
a plurality of different rotational positions via positioning nubs and
corresponding
positioning notches.
[0063] As shown in FIGS. 1-6, each of the first and second hubs 14, 20
includes a
barrier 38 extending generally perpendicularly from a portion of the hubs'
outwardly-facing
sides 32. In some embodiments, the barriers 38 may present a rounded outer
profile that
forms at least a portion of the outwardly-facing sides 32. The barriers 38 may
each
comprise a substantially planar member having two substantially flat sides. As
such, the
barriers 38 may each have the general shape of a half disk. In other
embodiments, the
barriers 38 may each have the general shape of a half sphere.
[0064] In some embodiments, as best illustrated in FIGS. 5-6, the first and
second
extension members 16, 22 will each comprise a main sidewall 40 and a perimeter
wall
42. The perimeter sidewalls 42 may extend away from the outwardly-facing sides
32 of
their respective extension member 16, 22. Furthermore, in some embodiments,
the
perimeter sidewalls 40 may be generally perpendicular to their respective main
sidewall
40. As such, the main sidewall 40 and perimeter sidewall 42 of each of the
first and
second extension members 16, 22 present an open void 44 bounded by the
sidewalls 40,
42.
[0065] As shown in FIGS. 1-2, embodiments further provide for the first and
second
extension members 16, 22 to each comprise an enlarged end portion 50, with the
end
portions 50 including oppositely facing heel portions 52 and toe portions 54.
In some
embodiments, the end portions 50 will include an end wall 56 that extends from
the
inwardly-facing side 30 of the first and second extension members 16, 22. The
end walls
56 of each of the first and second extension members 16, 22 are configured to
facilitate
receipt of concrete when portions of the first and second extension members
16, 22 are
embedded in concrete (as discussed in more detail below), so as to prevent
pullout of the
tie system 10 from the concrete. In other embodiments (not shown in the
figures), each
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end portion 50 may further comprise a holding aperture extending through a
thickness of
the end portion 50. As such, the holding apertures may be configured to
receive concrete
when the end portions 50 are embedded in concrete, so as to prevent pullout of
the tie
system 10 from the concrete.
[0066] Turning to FIG. 3, the tie system 10, as described above, is capable of
being
held in a plurality of different rotational positions. For example, FIG. 3
illustrates the tie
system 10 in an expanded configuration, i.e., with both the first and second
structural
members 12, 18 in solid-line. Alternatively, FIG. 3 also illustrates the tie
system 10 in a
partially-collapsed configuration, i.e., with the first structural member 12
in solid line and
the second structural member 18 in dashed-line. As will be discussed in more
detail
below, in a collapsed configuration, the tie system 10 can be inserted into an
opening
formed in an insulation layer used in an insulated concrete panel. After the
tie system 10
has been inserted in the opening of the insulation layer, the tie system can
be transitioned
to the expanded configuration where concrete can be poured about the tie
system 10 and
the insulation layer for manufacturing the insulated concrete panel.
[0067] The first and second structural members 12, 18 of the tie system 10 can
be
supplied to an insulated concrete panel maker (e.g., a "pre-caster") in the
disassembled
configuration (i.e., with the first and second structural members 12, 18
decoupled from
one another). In general, a plurality of the tie systems 10 can used by the
panel maker to
rigidly connect two layers of concrete that have an insulation layer, such as
an expanded
or extruded polystyrene board, positioned between the concrete layers. In
other
embodiments, insulation layers can be formed from expanded polystyrene,
polyisocyanurate, expanded polyethylene, extruded polyethylene, or expanded
polypropylene. To initiate manufacture of the insulated concrete panel, the
panel maker
can select the unassembled first structural member 12 and the second
structural member
18 and then connect them to one another, as previously described, by inserting
the hub
projection 24 of the first structural member 12 into the hub recess 26 of the
second
structural member 18.
[0068] As illustrated by FIG. 7, once the tie system 10 is assembled, it can
be
prepared for insertion into a tie opening 60 that has been formed in an
insulation layer 62
(e.g., a panel or a board) so as to manufacture an insulated concrete panel.
The tie
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opening 60 may be substantially cylindrical and may be formed using a hand
drill and a
core bit. However, embodiments may provide for the tie opening 60 to have
other shapes
and to be formed from other methods. Prior to insertion into the tie opening
60, the tie
system 10 is shifted into a collapsed configuration, where a width Wc between
adjacent
end portions 50 of each of the first and second extensions members 16,22 is
minimized
to be less than a width Woof the tie opening 60 and/or less than a width of
the hubs 14,
20 of the structural members 12, 18. As best illustrated by FIGS. 7-9, when
the tie system
is in the collapsed configuration, its length (measured along an axis of
elongation 61)
is maximized and its width is minimized so that it can then be inserted into
tie opening 60
of the insulation layer 62 until the hubs 14, 20 of the tie system are
substantially centered
in the tie opening 60.
[0069] As illustrated by FIGS. 10-11, once the hubs 14, 20 of the tie system
10 are
received in the tie opening 60, the tie system 10 can be shifted into the
expanded
configuration. As shown in FIG. 10, in the expanded configuration, a width We
between
the adjacent end portions 50 of each of the first and second extension members
16, 22
is maximized to be greater than the width Wo of the tie opening 60 (see FIG.
7) and/or
greater than the width of the hubs 14, 20. In certain embodiments, a ratio of
We to Wc of
the tie system 10 is at least 1.2:1, 1.5:1, 2:1, or 3:1. As such, shifting of
the tie system 10
from the collapsed configuration to the expanded configuration increases a
maximum
width of the tie system 10 and decreases a maximum length of the tie system
10. As such,
when the tie system 10 is in the collapsed configuration a maximum width of
the tie system
10 is less than a maximum width of the first and second hubs 14, 20 and the
tie opening
60, and when the tie system 10 is in the expanded configuration the maximum
width of
the tie system 10 is greater than the maximum width of the first and second
hubs 14, 20
and the tie opening 60.
[0070] As best illustrated in FIGS. 9 and 11, in certain embodiments, the tie
system
10 may be described as having first and second end sections 64, 66. The first
end section
64 may comprise one of the end portions 50 of the first extension member 16
and the
adjacent end portion 50 of the second extension member 22. Similarly, the
second end
section 66 may comprise the other end portion 50 of the first extension member
16 and
the adjacent end portion 50 of the second extension members 22. Given such
definitions,
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the width of the first and second end sections 64, 66 are defined as the width
Wc when
the tie system is in the collapsed configuration, and the width of the first
and second end
sections 64, 66 are defined as the width We when the tie system 10 is in the
expanded
position. As such and in the expanded configuration, maximum widths of the
first and
second end sections 64, 66 are each greater than the maximum width of the tie
opening
60, and in the collapsed configuration, maximum widths of the first and second
end
sections 64, 66 are each less than the maximum width of the tie opening 60.
[0071] As illustrated in FIG. 10, in the expanded configuration, the end
portions 50
of the extension members 16, 22 engage the insulation layer 62 in four contact
locations
68 located outside of, but proximate to, the tie opening 60. Two of these
contact locations
68 are on one side of the insulation layer 62 and the other two of the contact
locations 68
are on the opposite side of the insulation layer 62. As previously described,
the end
portions 50 of each extension member 16, 22 are enlarged relative intermediate
portions
of the extension members 16, 22. Such an enlargement provides for the heel 52
to
engage a surface of the insulation layer 62 and the toe 54 to extend outwardly
from the
surface of the insulation layer 62.
[0072] In certain embodiments, as shown in FIGS. 10-11, the rounded outer
profiles of the barriers 38 of each of the hubs 14, 20 substantially conform
to a cross-
sectional shape of the tie opening 60. When the tie system 10 is received in
the tie
opening 60 and placed in the expanded configuration, the hubs 14, 20,
including the
barriers 38, fill up a substantial portion of the cross-sectional area of the
tie opening 60.
Such filling up being due, in part, to the barriers 38 of the first and second
hubs 14, 20
being more closely aligned with one another when the tie system 10 is in said
expanded
configuration (i.e., FIGS. 10-11) than when the tie system 10 is in said
collapsed
configuration (i.e., FIGS 8-9). In certain embodiments, the hubs 14, 20,
including the
barriers 38, fill at least 70%, 80%, 90%, or 100% of the cross-sectional area
of the tie
opening 60 when the tie system 10 is in the expanded configuration. By filling
up a
substantial portion of the cross-section area of the tie opening 60, the
barriers 38 are
configure to thermally isolate layers of concrete that will be placed on
opposite sides of
the insulation layer 62.
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[0073] To further enhance the thermal isolation properties of the tie system
10, it
is preferred for the barriers 38, the hubs 14, 20, and/or the entire tie
system 10 to be
formed of, or coated with, a material having a thermal conductivity that is
less than steel,
preferably less than concrete. For instance, the barriers 38, the hubs 14, 20,
and/or the
entire tie system 10 may be formed of, or coated with, a material having a
thermal
conductivity less than 10, 5, 1, 0.5, or 0.1 W/(m.K). In some embodiments, the
barriers
38, the hubs 14, 20, and/or the entire tie system 10 may formed from a
synthetic resin,
such as an epoxy. In further embodiments, the synthetic resin may include
reinforcing
fibers, such as glass fibers and/or carbon fibers.
[0074] As illustrated in FIG. 12, after the tie system 10 has been inserted
into a tie
opening 60 of an insulation layer 62, and after the tie system 10 has been
shifted into the
expanded configuration so as to engage the insulation layer 62, an insulated
concrete
panel 70 can be manufacture by pouring top and bottom concrete layers 72, 74
on
opposite sides of the insulation layer 62. The insulated concrete panel can
have a variety
of sizes. For some insulated concrete panels, tie systems 10 will be
positioned throughout
the insulated concrete panels approximately every 8 to 10 square feet (FIG. 12
may not
be drawn to scale, but is provided for illustration of an insulated concrete
panel having a
plurality tie systems 10 included therein). In some cases of high loading, the
tie systems
will need to be positioned closer together. Typical insulated concrete panels
can
include between 10 to 100, between 20 to 80, or between 25 to 40 tie systems
10 within
each insulated concrete panel. In some embodiments, the plurality of tie
systems 10 can
be arranged in rows or columns that are aligned along a longitudinal or
transverse
direction of the insulated concrete panel 70 or at any other angle as deemed
necessary
by an engineer. Furthermore, each of the individual tie systems 10 can be
aligned (i.e.,
the first and second end sections 64, 66 can be aligned) along a longitudinal
or transverse
direction of the insulated concrete panel 70 or at any other angle as deemed
necessary
by an engineer. In other embodiments, outer panels, such as facades may be
positioned
exterior of the top and bottom layers of concrete 72, 74.
[0075] With continued reference to FIG. 12, to form the insulated concrete
panel
70, the bottom layer of concrete 74 is poured in a concrete form. Immediately
following
pouring the bottom layer of concrete 74, the insulation layer 62 with tie
systems 10
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coupled thereto can be lowered into engagement with the bottom layer of
concrete 74.
The end portions 50 of the tie systems 10 that extend down from a bottom
surface of the
insulation layer 62 become inserted into and embedded in the bottom layer of
concrete
74. The bottom surface of the insulation layer 62 may be inserted within at
least a top
surface of the bottom layer of concrete 74. Reinforcement in the form of
rebar, steel mesh,
or prestress strand may also be inserted into the bottom layer of concrete 74.
In some
cases the tie systems 10 may need to be turned in the tie opening 60 or even
relocated
a few inches away, so as to avoid contact with any such reinforcements. The
tie system
may be flexible enough to accommodate such turning and/or relocation.
[0076] Subsequent to placing the insulation layer 62 and tie systems 10 on
and/or
in the bottom layer of concrete 74, the top layer of concrete 72 can be poured
on a top
surface of the insulation layer 62. When the top layer of concreted 72 is
poured, the end
portions 50 of the tie systems 10 that extend up from the top surface of the
insulation
layer 62 become embedded in the top layer of concrete 72. During pouring of
the top
layer of concrete 72, the barriers 38 of the tie systems 10 inhibit passage of
concrete from
the top layer 72 entirely through the tie opening 60 in the insulation layer
62 and into
contact with the bottom layer of concrete 74. As such, a continuous air void
can be
maintained in the tie opening 60, above the bottom layer of concrete 74 and
below the
barriers 38. In some embodiments, however, at least a portion of the tie
opening 60 will
be filled with concrete from the first and/or second layers of concrete 72,
74. Nevertheless,
embodiments provide for at least 10%, 20%, 30%, or 40% of a volume of the tie
opening
60 to be filled with the air void. Such an air void improves thermal isolation
between the
top and bottom layers of concrete 72, 74, even with such top and bottom layers
72, 74
being indirectly connected via the tie systems 10.
[0077] As such, embodiments of the present invention include an insulated
concrete panel 70 comprising: an insulation layer 62 with a tie opening 60
extending
therethrough, first and second concrete layers 72, 74 disposed on generally
opposite
sides of the insulation layer 62, and at least one tie system 10
interconnecting the
concrete layers. As discussed above, the tie system 10 may comprise: hubs 14,
20
(collectively, a "hub portion") at least partly receive in the tie opening 60
of the insulation
layer 62, a first end section 64 at least partly embedded in the first
concrete layer 72, and
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a second end section 66 at least partly embedded in the second concrete layer
74, with
the tie system 10 being capable of shifting from a collapsed configuration, in
which a
maximum width Wc of the first and second end sections 64, 66 is less than a
maximum
width Wo of the tie opening 60, to an expanded configuration, in which the
maximum
width We of the first and second end sections 64, 66 is greater than the
maximum width
Wo of the tie opening 60.
[0078] Thus, as illustrated in FIG. 13, embodiments of the present invention
include
a method 1300 of making an insulated concrete panel. The method 1300 includes
the
initial Step 1302 of creating a tie opening that extends through an insulation
layer. A next
Step 1304 includes inserting an expandable tie system into the tie opening.
Thereafter,
in Step 1306, while the tie system is received in the tie opening and with
opposite ends
of the tie system extending out of the tie opening, shifting the tie system
into an expanded
configuration where a maximum width of the tie system is greater than a
maximum width
of the tie opening. In final Step 1308, while the tie system is in the
expanded configuration,
a layer of concrete is formed on each side of the insulation layer so that
opposite end
portions of the tie system are embedded in the opposite layers of concrete,
thereby
physically coupling the layers of concrete to one another using the tie
system. Once the
top and bottom layers of concrete 72, 74 have at least partially cured, the
concrete form(s)
(if used) can be removed and the concrete insulation panel 70 is prepared to
be lifted and
or shipped to a jobsite for installation.
[0079] As illustrated in the drawings, the tie systems 10 are generally formed
so as
to present an "X" shape with an intersection of the X-shape being located at
the hubs 14,
20. The "X" shape of the tie systems 10 allows for the tie systems 10 to
effectively transfer
shear forces between the layers of concrete 72, 74 without deforming the
insulation layer
62 therebetween. As such, the resulting insulated concrete panel 70 is
configured as a
composite panel. The tie system 10 is also configured to act as a tension
member that
will prevent the top and bottom layers of concrete 72, 74 from delamination
during lifting
and shipping. Further, as mentioned, the insulated concrete panel 70 can be
reinforced
with rebar, steel mesh, post tension cables, prestress strand, or a
combination of
reinforcement as needed by the particular job requirements so as to further
reinforce the
insulated concrete panel 70.
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Multi-Material Tie Device and System
[0080] Embodiments of the present invention provide for an additional
embodiment
of a tie system, which is illustrated as tie system 80 in FIGS. 14-15. The
additional tie
system 80 functions in substantially the same manner as the tie system 10
depicted in
FIGS. 1-13; however, each structural member 12, 18 of the additional tie
system 80 is
formed from more than one material. In more detail, in the additional tie
system 80
depicted in FIGS. 14-15, a material of construction of each of the tie
system's 80 hubs
14, 20 is different that a material of construction of each of the extension
members 16,
22. Specifically, the extension members 16, 22 may be separable from the hubs
14, 20,
respectively.
[0081] For example, each of the extension members 16, 22 may include a base 82
comprising extension connection elements 84. In certain embodiments, such
connection
elements 84 of the extension members 16, 22 will further include protrusions
88 (See
FIG. 15). Correspondingly, each of the hubs 14,20 may include connection
elements 86.
Such connection elements 86 of the hubs 14, 20 may be formed with cavities 90
(See
FIG. 14). In such embodiments, the protrusions 88 may be configured to be
received
within the cavities 90, such that the extension members 16, 22 can be
removable secured
to the hubs 14, 20.
[0082] Given the above, each of the extension members 16, 22 can be formed of
a material of high thermal conductivity (e.g., steel), while each of the hubs
14, 20 can be
formed of a material of low thermal conductivity (e.g., a synthetic resin or
fiber-reinforced
composite material). Such a configuration allows for an ultra-high strength,
thermally
conductive material to be used for the extension members 16, 22 (for
transmitting shear
forces though a relatively small section), and for a thermally insulating
material to be used
for the hubs 14, 20 (for inhibiting heat transfer). In certain embodiments,
the high strength
material (e.g., steel) used for the extension members 16, 22 will provide for
the tie
systems 80 to have a tensile strength of at least 10,000 psi. The insulating
material used
for the hubs 14, 20 may include a synthetic resin, such as an epoxy. In some
embodiments, a ratio of the thermal conductivity of the material used in the
extension
members 16,22 to the material used for the hubs 14,20 can be at least 2:1, at
least 5:1,
at least 10:1, or at least 50:1. For instance, the thermal conductivity of the
extension
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members 16, 22 can be at least 1, at least 5, at least 10, or at least 20
W/(m.K), while the
thermal conductivity of the hubs 14,20 can be less than 5, less than 2, less
than 1, less
than 0.5, or less than 0.1 W/(m.K).
[0083] As shown in FIGS. 14-15, the inwardly-facing side 30 of the first
structural
member 12 can include one or more positioning nubs 92 (See FIG. 14), while the
inwardly
facing side 30 of the second structural member 18 can be configured with a
plurality of
spaced-apart positioning notches 94 (See FIG. 15). The positioning notches 94
are sized
and located to receive the positioning nubs 92 as the first and second
structural members
12, 18 are rotated relative to one another. When the positioning nubs 92 are
received in
the positioning notches 94, relative rotation of the first and second
structure members 12,
18 is inhibited. As with the previously-described ribs 34, having a plurality
of positioning
notches 94 at different locations enables the first and second structural
members 12, 18
of the additional tie system 80 to be "locked" in various relative rotational
positions. As
such, the additional tie system 80 can be used with insulation layers of
varying thickness.
[0084] In certain embodiments, the extension members 16, 22 are manufactured
first and then placed in a mold for connection with the hubs 14, 20 while the
hubs 14, 20
are being manufactured. In this manner, the hubs 14, 20 can be formed around
connection elements 84 at the base 82 of each extension member 16, 22 to
ensure a
strong and secure connection between the extension members 16, 22 and the hubs
14,
20. When the hubs 14, 20 are formed of a synthetic resin material, the
extension members
16, 22 can be coupled to the hubs 14, 20 by first inserting the bases 82 of
the extension
members 16, 22 into a mold (e.g., an injection molding form) and then
introducing the
synthetic into the form so that the resin surrounds the connection elements 84
at the base
82 of the extension members 16, 22. If it is desired for the hub to be formed
of a fiber-
reinforce composite material, the reinforcing fibers can be placed in the mold
before
and/or during addition of the synthetic resin. In other embodiments, the
extension
members 16,22 and hubs 14,20 can be separately manufactured and then later
attached
to one another via any know fastening mechanisms such as, for example, screws,
bolts,
press-fitting, etc.
[0085] In further embodiments, each of the four extension members 16, 22 that
make up the additional tie system 80 can have an identical configuration,
thereby
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reducing manufacturing costs. Additionally, each of the two hubs 14, 20 of the
additional
tie system 80 can initially be manufactured with an identical configuration
and then later
modified to mate with one other. For example, both hubs 14, 20 of the
additional tie
system 80 can be being identically manufactured with the hub recess 26 and no
hub
projection 24. As such, when both hubs 14, 20 are identically manufactured
with a hub
recess 26, a separately manufactured hub projection 24 can be inserted (e.g.,
press-fit)
into one of the hub recesses 26 after initial manufacturing of the hubs 14,
20, thus allowing
one of the hubs 14, 20 to be provided with a hub projection 24 that can be
matingly
received in the hub recess 26 of the other hub 14, 20.
[0086] As previously described, the extension members (e.g., 16 or 22) can be
formed of a metallic material, such as steel. Although not illustrated in the
drawings, in
certain embodiments, the extension members (e.g., 16 or 22) may be formed by
cutting
an initial flat elongated member from a large sheet and then bending the flat
member into
the final shape of an extension member (e.g., 16 or 22). Such cutting may
include
stamping the elongated flat member out of the metallic sheet. The bending
forms the
perimeter sidewalls 42 at the outer perimeter of the extension members (e.g.,
16 or 22)
and also forms the connection elements 84 at the base 82 of the extension
members (e.g.
16, 22). As such, the two extension members (e.g., 16 or 22) can be rigidly
connected via
a hub (e.g., 14 or 20).
[0087] For instance, in some embodiments, the hub (e.g., 14 or 20) can be
formed
around the base 82 of the extension members (e.g., 16 or 22) so that said base
82 of
each of the extension members (e.g., 16 or 22) is at least partly embedded in
the hub
(e.g., 14 or 20). In more detail, the base 82 of each of the extension members
(e.g., 16
or 22) may be placed in a hub form and thereafter the hub form may be filled
with a
synthetic resin to thereby form the hub (e.g., 14 or 20). As previously
described, the
synthetic resin may include an epoxy. In further embodiments, reinforcing
fibers (e.g.,
glass fibers and/or carbon fibers) can be included in the hub form before
and/or during
filling of the hub form with said synthetic resin. Furthermore, in some
embodiments the
hub (e.g., 16 or 22) may include a hub recess 26. As such, a hub projection 24
may be
inserted into the hub recess 26 and attached to the hub recess 26 via press-
fitting.
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[0088] The previously-described bending of the flat members forms the
perimeter
sidewalls 42 which may be bent substantially perpendicular to the main
sidewall 40 of the
extension members (e.g., 16 or 22). As such, an open void 44 is defined within
the
perimeter sidewalls 42 of the extension members (e.g., 16 or 22). In certain
embodiments,
the bending further forms the connection elements 84 at the base 82 of the
extension
members (e.g., 16, 22), with such connection elements 84 being used to secure
the
extension members (e.g., 16, 22) to the hub (e.g., 14 or 20), as previously
described.
[0089] The multi-material tie system shown in FIGS. 14-15 can be used to form
an
insulated concrete panel 70 in the same manner as describe above with respect
to the
single-material tie system shown in FIGS. 1-13. Thus, a description of how the
multi-
material tie system is positioned into the insulation layer 62 and then used
to connect top
and bottom concrete layers 72, 74 on each side of the insulation layer 62 is
the same as
described above for tie system 10.
[0090] Although the invention has been described with reference to the
embodiments illustrated in the attached drawing figures, it is noted that
equivalents may
be employed and substitutions made herein without departing from the scope of
the
invention as recited in the claims.
Additional Embodiments
[0091] In addition to the embodiments described above, embodiments of the
present invention include a tie system 100, as illustrated in FIGS. 16-19, for
use in forming
an insulated concrete panel. The tie system 100 may be similar in many
respects to the
tie system 10 of FIGS. 1-6. For instance, any one or more of the dimensions,
features,
components, and functionalities of the tie system 10 may be applicable to
and/or included
within the tie system 100 illustrated in FIGS. 16-19. For instance, the tie
system 100 may
include the first structural member 12 comprising first hub 14 and pair of
first extension
members 16. The tie system 100 may also include the second structural member
18
comprising second hub 20 and pair of second extension members 22. In some
embodiments, as illustrated in the drawings, the tie system 100 will have a
generally C-
shaped cross section. As with tie system 10, the first and second hubs 14,20
of the tie
system 100, are rotatably coupled with one other in a manner that permits
rotation of the
first and second structural members 12, 18 relative to one another about an
axis of
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rotation extending through the first and second hubs 14, 20. As a result, the
first and
second structural members 12, 18 of the tie system 100 can be rotatably
coupled to one
another in a similar scissor-like configuration as the tie system 10 from
FIGS. 1-6, such
that the tie system 100 is capable of shifting between collapsed and expanded
configurations.
[0092] Furthermore, with respect to the tie system 100 and as perhaps best
illustrated by FIGS. 18 and 19, the hub 14 of the first structural member 12
may be
equipped with hub projection 24, and the hub 20 of the second structural
member 18 may
be equipped with hub recess 26. In contrast to the tie system 10 illustrated
in FIGS. 1-6,
however, the hub recess 26 of tie system 100 may not extend entirely through
the
thickness of the second structural member 18. Instead, the hub recess 26 may
extend
only partially from inwardly-facing side 30 of the second structural member
18. As such,
the outwardly-facing side 32 of the second structural member 18 may not have
an
openings extending entirely therethrough the hub 20. Nevertheless, the hub
projection 24
and the hub recess 26 may be formed with complementary sizes, such that the
hub
projection 24 can be received within the hub recess 26 in the assembled
configuration,
such as shown in FIGS. 16-17. As such, the tie system 100 can be assembled by
inserting
the hub projection 24 into the hub recess 26. In such an assembled
configuration, the
receipt of the hub projection 24 in the hub recess 26 inhibits translation of
the first and
second structural members 12, 18, while permitting rotation of the first and
second
structural members 12, 18 relative to one another via the axis of rotation.
[0093] Embodiments of the present invention provide for one or more of the
components of the tie system 100 to be formed from compression molding, in
which the
material of the tie system 100 is positioned within a steel form and placed
under high
temperatures (e.g., over 300 degrees Fahrenheit) and high pressures (e.g.,
over 100
tons). In some alternative embodiments, one or more components of the tie
system 100
may be formed by injection molding. In some embodiments, the first and second
structural
members 12, 18 of the tie system 100 may formed from a resin, such as a vinyl
resin. In
some embodiments, the first and second structural members 12, 18 (including
the hubs
14, 20) of the tie system 100 to be formed from and/or coated with a material
having a
thermal conductivity that is less than steel and less than concrete. For
instance, the first
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and second structural members 12, 18 of the tie system 100 may be formed of,
or coated
with, a material having a thermal conductivity less than 10, 5, 1, 0.5, or 0.1
W/(m.K). In
certain embodiment, the material will have a thermal conductivity of about 0.3
W/(m.K).
In some embodiments, the resin may include reinforcing fibers, such as glass
fibers
and/or carbon fibers. In some embodiments, the first and second structural
members 12,
18 of the tie system 100 may be formed from a material having between 15 to 65
or
between 20 to 50 percent vinyl ester resins and between 35 to 85 or between 50
to 80
percent long glass fibers, such that the tie system 100 comprises a strong,
alkali resistant
composite. In some specific embodiments, the first and second structural
members 12,
18 of the tie system 100 may be formed from a material having 35 percent vinyl
ester
resins and 65 percent long glass fibers. In certain embodiments, molding forms
for each
of the first and second extension members 12, 18 may be filled with the vinyl
ester resin
to thereby form the extension members 12, 18. In certain embodiments,
reinforcing fibers
(e.g., glass fibers and/or carbon fibers) can be included in the molding forms
before and/or
during filling of the molding form with the vinyl ester resin.
[0094] Additionally, in contrast to the tie system 10 that includes the
generally
planar barriers 38 illustrated in FIGS. 1-6, the tie system 100 may comprise
spherical
barriers 102 having a three-dimensional spherical shape. For instance, as
illustrated by
FIGS. 16-19, the barriers 102 may have the general form of a half-sphere. In
other
embodiments, the barriers 102 may have other shapes, such as a partial sphere,
a partial
oval, or the like. In some embodiments, the each of the barriers 102 may have
portions
their surfaces flattened so as to present planar side surfaces 104. The tie
system 100
may include two barriers 102, with one operable to extend from the outwardly-
facing sides
32 of each of the first and second structural members 12, 18. The barriers 102
may be
positioned on the first and second structural member 12, 18, such that the
side surfaces
104 are generally perpendicularly with an exterior surface 105 of the end
portions 50 that
connects the heel and toe portions 52, 54. The barriers 102 may not be
integral with the
first and second structural member 12, 18, such that the barriers 102 can be
selectively
engaged with and removed from the first and second structural member 12, 18.
To
accomplish such engagement, the first and second structural member 12, 18 may
include
protrusions 106 that extend from the outwardly-facing surfaces 32 of the hub
portions of
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the first and second structural member 12, 18. Such protrusions 106 may be
sized to form
a friction fit with openings 108 formed through a portion of the barriers 102.
As such, the
protrusions 106 will be engaged with the openings 108 to secure the barriers
102 to the
first and second structural member 12, 18. In some additional embodiments,
each of the
first and second structural member 12, 18 may also include one or more gussets
109 on
the outwardly-facing surfaces 32 of the hubs 14, 20 of the first and second
structural
member 12, 18, with such gussets bounding a seating area for receiving the
barriers 102.
With the barriers 102 positioned within such seating areas, the gussets 109
may overlap
at least a portion of the barrier 102 so as to provide a partial seal or a
dam, for inhibiting
fluid, liquid, or concrete from passing between the barriers 102 and the first
and second
structural members 12, 18.
[0095] The barriers 102 may be formed from materials that are different than
the
materials form which the first and second structural member 12, 18 are formed.
Specifically, the barriers 102 may be formed from foam or other insulation
type material,
such extrude or expanded polystyrene, polyisocyanu rate, expanded
polyethylene,
extruded polyethylene, or expanded polypropylene. Alternatively, the first and
second
structural member 12, 18 may be formed from various types of polymers. In
further
alternatives, the barriers 102 may be formed from the same material of which
the
insulation layers are formed (e.g., fiber-reinforced vinly).
[0096] Finally, in contrast to the end walls 56 of the tie system 10, the tie
system
100 may include one or more pegs 110 that extend out from the inner-facing
surfaces 30
of the end portions 50 of the first and second extension members 16, 22 of the
first and
second structural member 12, 18. The pegs 110 are configured to facilitate
engagement
with concrete when portions of the first and second extension members 16, 22
are
embedded in such concrete (as discussed in more detail below), so as to
prevent pullout
of the tie system 100 from the concrete. In some embodiments, the pegs 110
will extend
from the inner-facing surfaces 30 in a tapered manner.
[0097] As with tie system 10, in a collapsed configuration, the tie system 100
can
be inserted into an opening formed in an insulation layer used in an insulated
concrete
panel. In some embodiments, the insulation layer may comprise expanded or
extruded
polystyrene board. In other embodiments, the insulation layer can be formed
from
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expanded polystyrene, polyisocyanurate, expanded polyethylene, extruded
polyethylene,
or expanded polypropylene. The insulation layers used in the insulated
concrete panels
may come in various standard sizes, such as insulation layers having
thicknesses of
about 2, 3, or 4 inches. After the tie system 100 has been inserted into the
opening of the
insulation layer, the tie system 100 can be transitioned to the expanded
configuration and
concrete can then be poured about the tie system 100 and both sides of the
insulation
layer for manufacturing the insulated concrete panel. The concrete used in the
production
of the insulated concrete panel can include fine and coarse aggregates and may
comprise
clean, hard, strong, and durable inert material, which is free of injurious
amounts of
deleterious substances. In some embodiments, the concrete should have a
minimum
twenty-eight day concrete strength of at least 2,000, at least 4,000, or at
least 5,000
pounds per square inch.
[0098] In more detail, to initiate manufacture of an insulated concrete panel,
the
panel maker can select the unassembled first and second structural members 12,
18 and
then connect them to one another, as previously described, by inserting the
hub projection
24 of the first structural member 12 into the hub recess 26 of the second
structural
member 18. Next, a barrier 102 can be securely engaged with each of the first
and second
structural members 12, 18, such that the tie system 100 is assembled as shown
in FIGS.
16-17. Thereafter, the tie assembly 100 can be inserted into a tie opening 60
that has
been formed in an insulation layer 62 (e.g., a panel or a board) so as to
manufacture an
insulated concrete panel. The tie opening 60 may be formed in a generally
cylindrically
shape using a hand drill and a core bit as was previously described. The tie
opening 60
may be formed spaced apart from a side edge of the insulation layer. Prior to
insertion
into the tie opening 60, the tie system 100 is shifted into a collapsed
configuration, where
it can then be inserted into tie opening 60 of the insulation layer 62. The
tie system 100
is inserted until the hubs 14, 20 of the tie system are substantially centered
in the tie
opening 60. With the hubs 14, 20 substantially centered, the barriers 102 may
also be
substantially centered.
[0099] With reference to FIGS. 20-21, once the hubs 14, 20 and the barriers
102
of the tie system 100 are received in the tie opening 60, the tie system 10
can be shifted
into the expanded configuration. In the expanded configuration, the end
portions 50 of the
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extension members 16, 22 engage and/or contact the insulation layer 62 in four
contact
locations 68 positioned outside of, but proximate to, the tie opening 60. Two
of these
contact locations 68 are on one side of the insulation layer 62 and the other
two of the
contact locations 68 are on the opposite side of the insulation layer 62. As
previously
described, the end portions 50 of each extension member 16, 22 are enlarged
relative
intermediate portions of the extension members 16, 22. Such an enlargement
provides
for the heel 52 to engage a surface of the insulation layer 62 and the toe 54
to extend
outwardly from the surface of the insulation layer 62. Advantageously, the tie
system 100
of embodiments of the present invention allows for self-centering of the ties
system 100
within the tie opening 60 regardless of the thickness of the insulation layer
62. Particularly,
with the tie system 100 in the collapsed configuration and at least partially
inserted within
the tie opening 60, the tie system 100 will automatically center itself when
transitioned to
the expanded configuration such that it can have each of its end portions 50
being
engaged with the surfaces of the insulation layer 62.
[00100] As illustrated in FIGS. 20-21, with the end portions 50
engaged with
the surfaces of the insulation layer 62, the side surfaces 104 of the barriers
102 will be
generally parallel with the surfaces of the insulation layer 62. As such, the
rounded outer
profiles of the barriers 102 on each of the hubs 14, 20 will substantially
conform to a cross-
sectional shape of the tie opening 60. When the tie system 100 is received in
the tie
opening 60 and placed in the expanded configuration, the hubs 14, 20,
including the
barriers 102, fill up a substantial portion of the cross-sectional area of the
tie opening 60.
In certain embodiments, the hubs 14, 20, including the barriers 102, fill at
least 80%, 90%,
95% or 100% of the cross-sectional area of the tie opening 60 when the tie
system 100
is in the expanded configuration. By filling up a substantial portion of the
cross-section
area of the tie opening 60, the barriers 104 are configure to thermally
isolate layers of
concrete that will be placed on opposite sides of the insulation layer 62.
[00101] As illustrated in FIG. 22, after the tie system 100 has been
inserted
into a tie opening 60 of an insulation layer 62, and after the tie system 100
has been
shifted into the expanded configuration so as to engage the insulation layer
62, an
insulated concrete panel 112 can be manufacture by pouring top and bottom
concrete
layers 72, 74 on opposite sides of the insulation layer 62. The insulated
concrete panel
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112 can have a variety of sizes and/or shapes. For some insulated concrete
panels, tie
systems 100 will be positioned throughout the insulated concrete panels
approximately
every 5 to 15 square feet, every 6 to 12 square feet, or every 8 to 10 square
feet (FIG. 22
may not be drawn to scale, but is provided for illustration of an insulated
concrete panel
112 having a plurality tie systems 100 included therein). Typical insulated
concrete panels
can include between 10 to 100, between 20 to 80, or between 25 to 40 tie
systems 100
within each insulated concrete panel. In some embodiments, the plurality of
tie systems
100 can be arranged in rows or columns that are aligned along a longitudinal
or transverse
direction of the insulated concrete panel 112 or at any other angle as deemed
necessary
by an engineer. Furthermore, each of the individual tie systems 100 can be
aligned (i.e.,
end sections of the tie systems 100 can be aligned) along a longitudinal or
transverse
direction of the insulated concrete panel 70 or at any other angle as deemed
necessary
by an engineer. In other embodiments, outer panels, such as facades, may be
positioned
exterior of the top and bottom layers of concrete 72, 74.
[00102] With continued reference to FIG. 22, to form the insulated
concrete
panel 112, the bottom layer of concrete 74 is poured in a bottom concrete form
(not
shown). In some embodiments, the concrete form will have interlaced rows
and/or
columns of reinforcement materials, such as rebar, steel mesh, or prestress
strand
positioned therein so as to provide for additional support for the concrete
panel 112. In
some embodiments, the bottom layer of concrete 74 will undergo vibration to
ensure
proper settling of the concrete. Immediately following pouring the bottom
layer of concrete
74, the insulation layer 62 with tie systems 100 inserted therein can be
lowered into
engagement with the bottom layer of concrete 74. The end portions 50 of the
tie systems
100 that extend down from a bottom surface of the insulation layer 62 become
inserted
into and embedded in the bottom layer of concrete 74. In some embodiments, one
or
more of the ties systems 100 may need to be adjusted so as to avoid
interference with
reinforcements materials (e.g., rebar) that may be positioned in the bottom
layer of
concrete 74. Furthermore, pressure may be exerted on the insulation layer 62
(such as
by walking on the insulation layer 62) so that the bottom surface of the
insulation layer 62
will be inserted at least partially within a top surface of the bottom layer
of concrete 74.
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[00103] Subsequent to placing the insulation layer 62 and tie systems
100 on
and/or into the bottom layer of concrete 74, a top concrete form (not shown)
can be
positioned over the insulation layer 62, and reinforcement materials can be
positioned in
the top form. Thereafter, the top layer of concrete 72 can be poured on a top
surface of
the insulation layer 62. In some embodiments, the top layer of concrete 72
will not be
poured until the bottom layer of concrete 74 has time to cure, such as for at
least three
hours. When the top layer of concreted 72 is poured, the end portions 50 of
the tie
systems 100 that extend up from the top surface of the insulation layer 62
become
embedded in the top layer of concrete 72. During pouring of the top layer of
concrete 72,
the barriers 102 of the tie systems 100 inhibit passage of concrete through
the tie
openings 60 in the insulation layer. As such, a separation can be maintained
in the tie
openings 60 between the top and bottom layers of concrete 72, 74. Such a
separation
enhances thermal isolation between the top and bottom layers of concrete 72,
74, even
with such top and bottom layers 72, 74 being indirectly connected via the tie
systems 100.
[00104] As illustrated in the drawings, the tie systems 100 are
generally
formed so as to present an X-shape with an intersection of the X-shape being
located at
the hubs 14, 20. The first and second structural members 12, 18 of the tie
systems 100
provide for the effective transfer of shear forces and restriction of
delannination forces
between the layers of concrete 72, 74 without deforming the insulation layer
62
therebetween. Specifically, the first and second structural members 12, 18 are
configured
to act similar to web members of a truss, with the concrete panels acting as
the flanges
(i.e., truss cords). Thus, the first and second structural members 12, 18 are
configured to
transfer tensile and compressive forces between the layers of concrete 72, 74.
In some
embodiments, the tie system 100 is also configured to transfer bending
moments.
Furthermore, however, the hubs 14, 20 in particular are configured to act as
interlocking
shear plates capable of transferring shear forces and being moments between
the first
and second extension members 16, 22 and, thus, the layers of concrete 72, 74.
For
instance, the hub 14 is engaged with the hub 20, via the projection/hub recess
24,26 and
the ribs 34, such that the first and second structural members 12, 18 are
configured to
transfer shear forces and restrict delamination forces between the layers of
concrete 72,
74. In particular, the tie system 100 is configured to transfer at least 500
pounds, at least
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1,000 pounds, at least 2,000 pounds, at least 5,000 pounds, at least 10,000
pounds, at
least 15,000 pounds, or at least 20,000 pounds and/or between 500 to 20,000
pounds,
between 1,000 and 15,000 pounds, or between 2,000 and 10,000 pounds of shear
force
between the layers of concrete. In addition, the tie system 100 is configured
to resist at
least 500 pounds, at least 1,000 pounds, at least 2,000 pounds, or at least
4,000 pounds
and/or between 500 to 4,000 pounds or between 1,000 and 2,000 pounds of
delamination
force between the layers of concrete. In addition, the tie system 100 is
configured to
include a tensile strength of at least 10,000 psi, at least 20,000 psi, at
least 30,000 psi, at
least 40,000 psi, at least 50,000 psi, or at least 60,000 psi and/or between
10,000 and
60,000 psi, between 20,000 and 50,000 psi, or between 30,000 and 40,000 psi.
Furthermore, the tie system 100 is configured to include a tensile modulus of
at least 1
million psi, at least 2 million psi, at least 3 million psi, at least 5
million psi, at least 6 million
psi, or at least 8 million psi and/or between 1 to 8 million psi, between 2 to
6 million psi,
or between 3 and 5 million psi.
[00105] As such, the resulting insulated concrete panel 112 is
configured as
a composite panel, in which the tie systems 100 prevent the top and bottom
layers of
concrete 72, 74 from delamination during lifting and shipping. Further, as
mentioned, the
insulated concrete panel 112 can be reinforced with rebar, steel mesh, post
tension
cables, prestress strand, or a combination of reinforcement as needed by the
particular
job requirements so as to further reinforce the insulated concrete panel 112.
[00106] Embodiments of the present invention additionally comprise a
tie
system 120, as illustrated in FIGS. 23-24, for use in forming an insulated
concrete panel.
In contrast to the tie systems 10 and 100 described above, the components of
the tie
system 120 may be formed as integral, monolithic unit. In particular, the tie
system 120
may comprise a central section 122, a first concrete engaging section 124
extending from
a first end of the central section 122 and comprising first and second
protrusion portions
126, and a second concrete engaging section 128 extending from a second end of
said
central section 122 and comprising first and second end portions 130. In some
embodiments, as illustrated in the drawings, the tie system 120 will have a
generally !-
shaped cross section. As will be described in more detail below, the tie
system 120 can
be used in an insulated concrete panel to structurally connect layers of
concrete
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separated by an insulation layer. Beneficially, the tie system 120 of
embodiments of the
present invention is configured to transfer shear forces and restrict
delannination forces
between such layers of concrete.
[00107] The central section 122 may be a shaped generally rectangular,
so
as to present opposite main surfaces 132, as well as opposite side surfaces
134. The
central section 122 may have a length (i.e., a length of the side surfaces 134
between the
first and second concrete engaging sections 124, 128) of between 2 to 6
inches, between
3 to 5 inches, or about 5 inches, a width (i.e., a distance between the side
surfaces 134)
of between 3 to 6 inches, between 4 to 5 inches, or about 4.5 inches, and a
thickness
(i.e., a distance between the main surfaces 132) of between about 0.5 to 3
inches, 1 to 2
inches, or about 1.5 inches. In some embodiments, the width of the central
section 122
is dependent on a size of the opening in the insulation layer in which the tie
system 120
will be positioned. In particular, and as will be described in more detail
below, the central
section 122 of the tie system 120 will be received within a tie opening in an
insulation
layer, such that the central section's 122 width will be the same size (or
slightly smaller in
size) as a diameter of such tie opening in the insulation layer. In some
embodiments, the
tie system 120 will be at least partially retained within the tie opening via
a friction fit, such
that the width of the central section 122 will be about the same size as the
diameter of
the tie opening. To further enhance the ability of the tie system 120 to be
retained within
the opening, certain embodiments of the present invention provide for the
central section
122 to include one or more tapered shim elements 136 positioned on its side
surfaces
134. In particular, the shim elements 136 may be tapered such that a portion
of the shim
elements 136 nearest the first end of the central section 122 extend from the
side surfaces
134 less than a portion of the shim elements 136 nearest the second end of the
central
section 122 extends from side surfaces 134.
[00108] The first concrete engaging section 124 includes the first and
second
protrusion portions 126 that extend generally from the central section 122.
The first and
second protrusion portions 126 may extend from the central section 122 in a
direction
that is generally parallel with a longitudinal axis of the tie system 120.
However, in other
embodiments, the protrusion portions 126 may extend from the central section
122 at
various different angles. In addition, the first and second protrusion
portions 126 may be
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spaced apart from each other, such that the protrusion portions 126 have
widths that are
less than about one-half the width of the central section 122. As such, the
first concrete
engaging section 124 may have a maximum width that is generally the same as
the
maximum width of the central section 122, i.e., between 3 to 6 inches, between
4 to 5
inches, or about 4.5 inches. Beneficially, the maximum width of the first
concrete
engaging section 124 is configured to allow for insertion of the tie system
120 within an
opening in an insulation layer, as is described in more detail below.
[00109] The second concrete engaging section 128 includes the first
and
second end portions 130 that extend from the central section 122 in a
direction generally
opposite the first and second protrusion portions 126 of the first concrete
engaging
section 124. In some embodiments, the end portions 130 may be configured and
sized
similar to the end portions 50 of tie systems 10 and 100. In such embodiments,
the end
portions 130 will include opposite heal and toe portions 138, 140. In certain
embodiments,
connecting surfaces 142 of the end portions 130 that connect each of the heel
and toe
portions 138, 140 will be generally parallel with the longitudinal axis of the
tie system 120.
In addition, the second concrete engaging section 128 may include extension
arms 144
that connect the end portions 130 to the central portion 122. The extension
arms 144 may
extend from the central section 122 at an angle with respect to the
longitudinal axis of the
tie system 120. As such, the end portions 130 may extend out further from the
longitudinal
axis than the central section 122, such that a maximum width of the second
concrete
engaging section 128 is larger than a maximum width of the central section 122
and/or
the first concrete engaging section 124. In particular, the end portions 130
may extend
away from each other, such that the second concrete engaging section 128 has a
width
of between 4 to 8 inches, between 5 to 7 inches, or about 6 inches.
Beneficially, the
maximum width of the second concrete engaging section 128 is configured to
inhibit
rotation of the tie system 120 when it is positioned within an opening of an
insulation layer,
as is described in more detail below.
[00110] In some embodiments, as shown in FIGS. 23-24, the tie system
120
may include barriers 146 that extend generally perpendicularly from the main
surfaces
132 of the central section 122. The barriers 146 may be positioned on the
central section
122 adjacent to the second concrete engaging section 128. In some embodiments,
the
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barriers 146 may present a rounded outer profile. The barriers 122 may each
comprise a
substantially planar member having two substantially flat sides. As such, the
barriers 146
may each have the general shape of a half disk. In other embodiments, the
barriers 146
may each have the general shape of a half sphere.
[00111] Embodiments of the present invention provide for the tie
system 120
to be formed from and/or coated with a material having a thermal conductivity
that is less
than steel and less than concrete. For instance, the tie system 110 may be
formed of, or
coated with, a material having a thermal conductivity less than 10, 5, 1, 0.5,
or 0.1
W/(m.K). In certain embodiment, the material will have a thermal conductivity
of about 0.3
W/(m.K). In some embodiments, tie system 120 may formed from a resin, such as
a vinyl
resin. In further embodiments, the synthetic resin may include reinforcing
fibers, such as
glass fibers and/or carbon fibers. In some embodiments, the tie system 120 may
be
formed from a material having between 15 to 65 or between 20 to 50 percent
vinyl ester
resins and between 35 to 85 or between 50 to 80 percent long glass fibers,
such that the
tie system 120 comprises a strong, alkali resistant composite. In some
specific
embodiments, the tie system 120 may be formed from a material having 35
percent vinyl
ester resins and 65 percent long glass fibers. Such a tie system 120 can be
formed from
compression molding, in which the material is placed within a steel form and
placed under
high temperatures (e.g., over 300 degrees Fahrenheit) and high pressures
(e.g., over 100
tons). In other embodiments, the tie system 200 may be injection molded.
[00112] As with tie systems 10 and 100, the tie system 120 can be
inserted
into an opening formed in an insulation layer used in an insulated concrete
panel. The
insulation layer may comprise expanded or extruded polystyrene board. In other
embodiments, insulation layers can be formed from expanded polystyrene,
polyisocyanurate, expanded polyethylene, extruded polyethylene, or expanded
polypropylene. The insulation layers may include standard sizes, such as
insulation layer
having 2, 3, or 4 inch thicknesses. After the tie system 120 has been inserted
in the
opening of the insulation layer, concrete can be poured about the tie system
120 and the
insulation layer for manufacturing the insulated concrete panel. The concrete
can include
fine and coarse aggregates that comprise clean, hard, strong, and durable
inert material,
which is free of injurious amounts of deleterious substances. In some
embodiments, the
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concrete should have a minimum twenty-eight day concrete strength of at least
2,000, at
least 4,000, or at least 5,000 pounds per square inch.
[00113] In more detail, and with reference to FIGS. 25-26, to initiate
manufacture of an insulated concrete panel, the panel maker can insert the tie
system
120 into a tie opening 60 that has been formed in an insulation layer 62
(e.g., a panel or
a board) so as to manufacture the insulated concrete panel. The tie opening 60
may be
formed in a generally cylindrically shape using a hand drill and a core bit as
previously
described. The tie opening 60 may be formed spaced apart from a side edge of
the
insulation layer. The tie system 120 is inserted (first concrete engaging
section 124 first)
into tie opening 60 of the insulation layer 62 until the central section 122
of the tie system
120 is received in the tie opening 60 and at least a portion of each of the
first and second
concrete engaging sections 124, 128 are extending from opposite sides of the
tie opening
60. Beneficially, the maximum width of the first concrete engaging section 124
is smaller
than the diameter of the tie opening 60, so as to allow for such insertion.
Furthermore,
the tie system 120 will be positioned such that the end portions 130 of the
second
concrete engaging section 128 engage and/or contact the insulation layer 62 in
two
contact locations 68 located outside of, but proximate to, the tie opening 60.
The two
contact locations 68 are on one side of the insulation layer 62. As previously
described,
the end portions 130 of the second concrete engaging section 128 are enlarged
relative
to the central section 122. Such an enlargement provides for the heel 138 to
engage a
surface of the insulation layer 62 and the toe 140 to extend outwardly from
the surface of
the insulation layer 62. In such a configuration, the tie system 120 is
ensured to be
inserted into the tie opening 60 at the right depth because the tie system 120
is restricted
from being inserted into the tie opening 60 past the point at which the end
portions 130
of the second concrete engaging section 128 come into contact with the
insulation layer
62. Furthermore, as described previously, the maximum width of the second
concrete
engaging section 128 is configured to inhibit rotation of the tie system 100
that may be
induced by shear forces that exist between concrete layers positioned on
either side of
the insulation layer 62.
[00114] In some embodiments, the tie system 120 can be maintained
within
the tie opening 60 by having the width of the central section 122 generally
the same size
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as the diameter of the tie opening 60, such that an interference fit is formed
between the
tie system 120 and the insulation material bounding the tie opening 60. In
certain
embodiments in which the central section 122 includes the tapered shim
elements 136
on its side surfaces 132, the tapered shim elements 136 may engage with the
insulation
material bounding the tie opening 60 so as to further restrict the tie system
120 from being
removed.
[00115] Furthermore, as illustrated in FIGS. 25-26, with the tie
system 120
positioned in the tie opening 60 as described above, the barriers 146 will be
generally
parallel with the surfaces of the insulation layer 62. In some embodiments,
the barriers
146 will be generally flush with a surface of the insulation layer.
Furthermore, the rounded
outer profiles of the barriers 146 will substantially conform to a cross-
sectional shape of
the tie opening 60. When the tie system 120 is received in the tie opening 60,
the central
section and the barriers 146, fill up a substantial portion of the cross-
sectional area of the
tie opening 60. In certain embodiments, central section 122 and the barriers
146, fill at
least 80%, 90%, 95% or 100% of the cross-sectional area of the tie opening 60.
By filling
up a substantial portion of the cross-section area of the tie opening 60, the
barriers 146
are configure to thermally isolate layers of concrete that will be placed on
opposite sides
of the insulation layer 62, as will be discussed in more detail below.
[00116] As illustrated in FIG. 26, after the tie system 120 has been
inserted
into a tie opening 60 of an insulation layer 62, an insulated concrete panel
150 can be
manufactured by pouring top and bottom concrete layers 72, 74 on opposite
sides of the
insulation layer 62. The insulated concrete panel 150 can have a variety of
sizes. For
some insulated concrete panels, tie systems 120 will be positioned throughout
the
insulated concrete panels approximately every 5-15, every 6-12, or every 8 to
10 square
feet (FIG. 26 may not be drawn to scale, but is provided for illustration of
an insulated
concrete panel 150 having a plurality tie systems 120 included therein).
Typical insulated
concrete panels can include between 10 to 100, between 20 to 80, or between 25
to 40
tie systems 120 within each insulated concrete panel. In some embodiments, the
plurality
of tie systems 120 can be arranged in rows or columns that are aligned along a
longitudinal or transverse direction of the insulated concrete panel 150 or at
any other
angle as deemed necessary by an engineer. Furthermore, each of the individual
tie
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systems 120 can be aligned (i.e., the first and second concrete engaging
sections 124,
128 can be aligned) along a longitudinal or transverse direction of the
insulated concrete
panel 70 or at any other angle as deemed necessary by an engineer. In other
embodiments, outer panels, such as facades may be positioned exterior of the
top and
bottom layers of concrete 72, 74.
[00117] With continued reference to FIG. 26, to form the insulated
concrete
panel 150, the bottom layer of concrete 74 is poured in a bottom concrete
form. In some
embodiments, the concrete form will have interlaced rows and/or columns of
reinforcement materials, such as rebar, steel mesh, or prestress strand
positioned therein
so as to provide for additional support for the concrete panel 150. In some
embodiments,
the bottom layer of concrete 74 will undergo vibration to ensure proper
settling of the
concrete. Immediately following pouring the bottom layer of concrete 74, the
insulation
layer 62 with tie systems 120 inserted therein can be lowered into engagement
with the
bottom layer of concrete 74. The protrusion portions 126 of the first concrete
engaging
section 124 of the tie systems 120 that extend down from a bottom surface of
the
insulation layer 62 become inserted into and embedded in the bottom layer of
concrete
74. In some embodiments, one or more of the tie systems 120 may need to be
adjusted
so as to avoid interference with reinforcements materials (e.g., rebar) that
may be
positioned in the bottom layer of concrete 74. Furthermore, pressure may be
exerted on
the insulation layer 62 (such as by walking on the insulation layer 62), such
that the bottom
surface of the insulation layer 62 will be placed into contact with and/or
inserted within at
least a top surface of the bottom layer of concrete 74.
[00118] Subsequent to placing the insulation layer 62 and tie systems
120 on
and/or into engagement with the bottom layer of concrete 74, a top concrete
form can be
positioned over the insulation layer, and reinforcement materials can be
positioned in the
top form. Thereafter, the top layer of concrete 72 can be poured on a top
surface of the
insulation layer 62. In some embodiments, the top layer of concrete 72 will
not be poured
until the bottom layer of concrete 74 has time to cure, such as for at least
three hours.
When the top layer of concreted 72 is poured, the end portions 130 of the
second concrete
engaging section 128 of the tie systems 120 that extend up from the top
surface of the
insulation layer 62 become embedded in the top layer of concrete 72. During
pouring of
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the top layer of concrete 72, the barriers 146 of the tie systems 120 inhibit
passage of
concrete from the top layer 72 through the tie opening 60 in the insulation
layer 62 and
into contact with the bottom layer of concrete 74. As such, a separation,
including an air
gap between the bottom layer of concrete 74 and the barriers 146, can be
maintained in
the tie opening 60. Such separation and air gap enhances thermal isolation
between the
top and bottom layers of concrete 72, 74, even with such top and bottom layers
72, 74
being indirectly connected via the tie systems 120.
[00119] As illustrated in the drawings, the tie systems 120 are
generally
formed with a rectangular shape, including a rectangular cross-section. As
such the tie
systems 120 can be presented in the form of a Vierendeel truss. The central
section 122,
the first concrete engaging section 124, and the second concrete engaging
section 128
of the tie systems 120 are interconnected via rigid, fixed connections, so as
to provide for
the effective transfer of shear forces and the restriction of delamination
forces between
the layers of concrete 72, 74 without deforming the insulation layer 62
therebetween.
Specifically, the first and second end portions 130 and the first and second
protrusion
portions 126 are configured to act as web members of a truss, with the layer
of concrete
72, 74 acting as the flanges (i.e., truss cords). Thus, the first and second
end portions
130 and the first and second protrusion portions 126 are configured to
transfer tensile
and compressive forces between the central section 122 and, thus, between the
layers
of concrete 72, 74. Furthermore, the central section 122, is configured to act
as a shear
plate capable of transferring shear forces and restricting delamination forces
between the
concrete layers. In some embodiments, the tie system 120 may also be
configured to
transfer bending moments between the concrete layers. In particular, the tie
system 120
is configured to transfer at least 500 pounds, at least 1,000 pounds, at least
2,000 pounds,
at least 5,000 pounds, at least 10,000 pounds, at least 15,000 pounds, or at
least 20,000
pounds and/or between 500 to 20,000 pounds, between 1,000 and 15,000 pounds,
or
between 2,000 and 10,000 pounds of shear force between the layers of concrete.
In
addition, the tie system 120 is configured to resist at least 500 pounds, at
least 1,000
pounds, at least 2,000 pounds, or at least 4,000 pounds and/or between 500 to
4,000
pounds or between 1,000 and 2,000 pounds of delamination force between the
layers of
concrete. In addition, the tie system 120 is configured to include a tensile
strength of at
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least 10,000 psi, at least 20,000 psi, at least 30,000 psi, at least 40,000
psi, at least 50,000
psi, or at least 60,000 psi and/or between 10,000 and 60,000 psi, between
20,000 and
50,000 psi, or between 30,000 and 40,000 psi. Furthermore, the tie system 120
is
configured to include a tensile modulus of at least 1 million psi, at least 2
million psi, at
least 3 million psi, at least 5 million psi, at least 6 million psi, or at
least 8 million psi and/or
between 1 to 8 million psi, between 2 to 6 million psi, or between 3 and 5
million psi.
[00120] As such, the resulting insulated concrete panel 150 is
configured as
a composite panel, in which the tie system 120 prevents the top and bottom
layers of
concrete 72, 74 from delamination during lifting and shipping. Further, as
mentioned, the
insulated concrete panel 150 can be reinforced with rebar, steel mesh, post
tension
cables, prestress strand, or a combination of reinforcement as needed by the
particular
job requirements so as to further reinforce the insulated concrete panel 150.
[00121] Additional embodiments of the present invention comprising a
generally X-shaped tie system 200 for use in making insulated concrete panels.
For
instance, FIGS. 27-30 illustrate various embodiments of the X-shaped tie
system 200 that
include a generally T-shaped cross-section. Nevertheless, it should be
understood that
embodiments of the preset invention contemplate the use of other shaped cross-
sections,
such as L-shaped, C-shaped, I-shaped, and U-shaped cross-sections. For
example, FIG.
31 illustrates an Embodiment of an X-shaped tie system 200 that includes an L-
shaped
cross-section.
[00122] Remaining with FIGS. 27-30, the tie system 200 broadly
comprises
a generally X-shaped component. In certain embodiments, the tie system 200 may
be
described as comprising first and second elongated structural members 202, 204
that are
integrally connected so as to form the X-shape. The first and second elongated
structural
members 202, 204 may each have lengths of between about 7 to 15 inches,
between
about 8 to 14 inches, or between about 9 to 13 inches. Nevertheless, it should
be
understood that the first and second elongated structural members 202, 204 may
be
formed with particular sizes as may be required for use of the tie system 200
with an
insulation layer, as will be discussed in more detail below. Each of the
elongated structural
members 202, 204 includes ends, with such ends being spaced apart from a
center of
the tie system 200. In some embodiments, and with continued reference to FIGS.
27-30,
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the first and second structural members 202, 204 intersect to form first
intersection angle
X and a second intersection angle Y. In some embodiments, the first
intersection angle X
will be an acute angle, and the second intersection angle Y will be an obtuse
angle.
Certain specific magnitudes for the first intersection angle X will be
described in more
detail below. In other embodiments, the first and second intersection angles
X, Y will be
generally equal. As an alternative description, the tie system 200 may be
defined as
comprising four integrally connected legs, with such legs connected so as to
form the X-
shape. As a further alternative description, the tie system 200 may be defined
as
comprising a central section opposed by first and second concrete engaging
sections,
with each of the first and second concrete engaging sections defined by
adjacent portions
of the first and second elongated structural members 202, 204 separated by the
second
intersection angle Y.
[00123] With reference to FIGS. 27-30, the tie system 200 may comprise
a
top section 206 that presents a generally present a flat, planar surface. The
top section
206 will provide support for the tie system 200 as it is inserted within an
insulation layer.
To facilitate such support, the top section 206 may have a width W (See FIG.
28) of
between about 0.5 to 3 inches, between about 1 to 2 inches, or about 1.25
inches. The
tie system 200 may include various features that extend from the top section
206, so as
to form the T-shaped cross-section. For instance, the tie system 200 may
include a
projection 208 that extends generally perpendicularly from a bottom surface of
the top
section 206. In some embodiments, the projection 208 is oriented so as to
extend parallel
with a centerline of the first and second elongated structural members 202,
204. As such,
the projection 208 correspondingly presents an X-shape. The tie system 200
includes a
recessed area 210 that is presented between the projection 208 and the bottom
surface
of the top section 206. For clarity, the recessed area may be defined as the
open space
existing within corner areas of the tie system 200 as is presented by the
intersection of
the projection 208 and the top section 206. As such, the recessed area 210 is
operable
to increase the overall surface area presented by the tie system 200. During
use of a tie
system 200, portions of the recessed areas 210 become filled with concrete,
adding to
the overall strength of the tie system 200.
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[00124] In some embodiments, a thickness of the projection 208 may
vary at
different positions about the tie system 200. For example, in some
embodiments, a
bottom-most portion of the projection may have a sharpened edge, which as will
be
described in more detail below, facilitates insertion of the tie system 200
within an
insulation layer. In some embodiments, such as illustrated in FIG. 30, some
bottom-most
portions of the projection 208 may have sharpened, teeth-like elements 212
that further
facilitate such insertions. In some embodiments, the teeth-like elements 212
will include
an arcuate shape, with such arcuate shapes including a radius of curvature of
about 0.25
inches, about 0.5 inches, about 0.75 inches, or about 1.0 inches. In other
embodiments,
the teeth-like elements 212 will comprise linear, triangular-shaped sections.
In even
further alternative embodiments, portions of the projection 208 near a center
of the tie
system 200 may have a smaller thickness than portions of the projection 208
near ends
of the first and second elongated structural members 202, 204. Such reductions
in
thickness may facilitate the insertion of the tie system 200 into an
insulation layer.
[00125] In some additional embodiments of the present invention,
various
portions of the projection 208 will extend different distances from the top
section 206. In
some embodiments, the entire projection 208 will extend a distance H (See FIG.
27)
between about 0.5 and 4 inches, between about 1 and 3 inches, or about 2
inches from
the top section 206. In other embodiments, portions of the projection near a
center of the
tie system 200 may extend a shorter distance from the top section 206 than
portions of
the projection 208 near the ends of the first and second elongated structural
members
202, 204. For instance, the center of the tie system 200 may not include a
projection 208
extending from the top section 206, while ends of the first and second
elongated structural
members 202, 204 may include a projection 208 extending therefrom a distance
H.
Similar to the reductions in thickness described previously, such reductions
in extension
distance may facilitate the insertion of the tie system 200 into an insulation
layer. In certain
embodiments, the variations in extension distances of the projection 208 will
also facilitate
proper positioning of the tie system 200 on an insulation panel. For example,
the tie
system 200 may be positioned on the insulation layer such that only the
portions of the
projection 208 that extend the shorter distance from the top section 206
(e.g., portions of
the projection 208 adjacent to the center of the tie system 200) will be in
contact with an
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insulation panel. As such, the portions of the projection 208 that extends the
longer
distance from the top section 206 (e.g., portions of the projection 208
adjacent to the ends
of the tie system 200) will be positioned adjacently to the insulation panel,
thereby acting
as a guide to restrict improper positioning of the tie system 200.
[00126] In additional embodiments, as illustrated in FIGS. 29 and 30,
the
projection 208 of the tie system 200 may include one or more tabs 214 that
project
laterally from the projection 208. Certain embodiments will provide for two or
more tabs
214 to be included with each of the first and second structural members 202,
204, such
that the tie system 200 will include four tabs 214. In some embodiments, the
tabs 214 on
the first and second structural members 202, 204 that are separated by the
first
intersection angle X will be separated by a linear distance D. Embodiments of
the present
invention provide for the distance D to be generally equivalent to a depth of
the insulation
panel in which the tie system 200 will be inserted. As such, the tabs 214 can
act as guides
for proper placement of the tie system 200. In some embodiments, the distance
D will be
at least 2 inches, at least 3 inches, or at least 4 inches, so as to
correspond with insulation
layer having a thickness of at least 2 inches, at least 3 inches, or at least
4 inches. The
tabs 214 may have various sizes and shapes, such as flat or rectangular
shapes. In the
embodiment shown in the figures for example, the illustrated tabs 214 are
generally
shaped as a triangular prism.
[00127] Furthermore, as shown in FIGS. 27-30 the tie system 200 may
include flaps 216 that extend generally perpendicularly from the bottom
surface of the top
section 206 adjacent to the ends of each of the first and second structural
members 202,
204. In some embodiments, the orientation of the flaps 216 will also provide
for them to
be generally perpendicular to the projection 208. The flaps 216 may be
operable to
provide for an increase the overall surface area presented by the tie system
200 so as to
increase the overall strength of the tie system 200 when the tie system 200 is
embedded
in concrete.
[00128] Embodiments of the present invention provide for the tie
system 200
to be formed in various sizes and shapes as may be appropriate for use with
insulation
layer of various sizes and shapes. For example, as previously described, the
tie system
200 can be used with commonly-sized insulation layers having a thickness of 2
inches, 3
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inches, or 4 inches. To facilitate the integration of the tie systems 200 with
insulation
layers of such thicknesses, the first intersection angle X of such tie systems
may be
approximately 35 degrees, approximately 37.5 degrees, and approximately 40
degrees,
respectively. Nevertheless, it should be understood that the first
intersection angle X of
the tie system 200 may have other magnitudes, as may be appropriate for
insulation layer
of different thicknesses.
[00129] Embodiments of the present invention provide for the tie
system 200
to be formed from and/or coated with a material having a thermal conductivity
that is less
than steel and less than concrete. For instance, the tie system 200 may be
formed of, or
coated with, a material having a thermal conductivity less than 10, 5, 1, 0.5,
or 0.1
W/(m.K). In certain embodiment, the material will have a thermal conductivity
of about 0.3
W/(m.K). In some embodiments, tie system 200 may formed from a resin, such as
a vinyl
resin. In further embodiments, the synthetic resin may include reinforcing
fibers, such as
glass fibers and/or carbon fibers. In some embodiments, the tie system 200 may
be
formed from a material having between 15 to 65 or between 20 to 50 percent
vinyl ester
resins and between 35 to 85 or between 50 to 80 percent long glass fibers,
such that the
tie system 200 comprises a strong, alkali resistant composite. In some
specific
embodiments, the tie system 200 may be formed from a material having 35
percent vinyl
ester resins and 65 percent long glass fibers, such that the tie system 120
comprises a
strong, alkali resistant composite. Such a tie system 200 can be formed from
compression
molding, in which the material is placed within a steel form and placed under
high
temperatures (e.g., over 300 degrees Fahrenheit) and high pressures (e.g.,
over 100
tons). In other embodiments, the tie system 200 may be injection molded.
[00130] As described above, the X-shaped tie systems 200 may be formed
to include cross-sections other than T-shaped. For instance, FIG. 31
illustrates a tie
system 200 having an L-shaped cross-section. In more detail, the tie system
broadly
comprising a generally X-shaped component, including first and second
elongated
structural members 202, 204 that are integrally connected so as to form the X-
shape. As
with the tie system 200 of FIGS. 27-30, the tie system 200 of FIG. 31 may
similarly provide
for the first and second structural members 202, 204 intersect to form an
acute first
intersection angle X and an obtuse intersection angle Y. Each of the elongated
structural
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members 202, 204 include first and second ends, with such ends space apart
from a
center of said tie system. The tie system 200 includes top section 206, which
may
generally be presented as a flat surface. The tie system 200 of FIG. 31 may
include
various features that extend from the top section, so as to form the L-shaped
cross-
section. For instance, the tie system may include a projection 208 that
extends generally
perpendicularly from a bottom surface of the top section 206. In some
embodiments, the
projection 208 is aligned with the first and second elongated structural
members 202,
204, such that the projection 208 is similarly presented in an X-shape. As
such, from a
bottom perspective, the tie system includes a recessed area 210 that exists
between the
projection 208 and the bottom surface of the top section 206.
[00131] In some embodiments, a portion of the projection 208 may have
a
sharpened edge, so as to facilitate the tie system 200 being inserted into an
insulation
layer, as will be discussed in more detail below. In additional embodiments,
the tie system
200 may include one or more flaps 218 that extend perpendicularly away from
the
projection 208 and/or the top section 206. Furthermore, in some embodiments,
one or
more of the flaps 218 may extend away from the recessed area 210 of the tie
system 200.
[00132] In certain embodiments, the tie system 200 with the L-shaped
cross
section, as illustrated in FIG. 31, can be formed by the following process: To
begin, the
first and second elongated structural members 202, 204 may be cut from a sheet
of pliable
material, such as a metals (i.e., steel, tin, aluminum, or the like) or
certain thermoplastic
polymers, such as polypropylene, polyethylene, polyethylene terephthalate,
polyamide,
vinyl-based polymers, the like, and combinations thereof. It being understood
that such
thermoplastic polymers my require the application of heat and/or pressure to
become
pliable. Next, an edge of each of the first and second elongated structural
members 202,
204 may be bent to thereby form the projection 208 extending from the top
section 206.
As such, the first and second elongated structural members 202, 204 having an
L-shaped
cross-section are formed. In some additional embodiments, portions of the ends
of the
first and second elongated structural members 202, 204 may be bent to thereby
form the
flaps 218 on the ends. Finally, the first and second elongated structural
members 202,
204 may be rigidly connected to form the tie system having the X-shape. Such a
connection can be formed by welding, heat treatment, adhesives, or the like.
As
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previously described, the recessed area 210 between the projection 208 and the
top
section 206 provides an open void/cavity operable to receive concrete so as to
add to the
overall strength of the tie system 200.
[00133] To form an insulated concrete panel, one or more of the X-
shaped
tie systems 200 may be used by a panel maker (e.g., a "pre-caster") to rigidly
connect
two layers of concrete that have an insulation layer, such as an expanded or
extruded
polystyrene board, sandwiched therebetween. In other embodiments, insulation
layers
can be formed from expanded polystyrene, polyisocyanurate, expanded
polyethylene,
extruded polyethylene, or expanded polypropylene. To initiate making of the
insulated
concrete panel, the panel maker can select a tie system 200 to be inserted
into a side
edge of an insulation layer. As described above, embodiments of the present
invention
provide for the tie system 200 to be formed in a plurality of sizes, so as to
be compatible
for use with insulation layers have a variety of thicknesses. As illustrative
examples, the
tie systems 200 may be used with insulation layers having thicknesses of about
2 inches,
about 3 inches, or about 4 inches. Insulation layers having thicknesses of 2
inches, 3
inches, and 4 inches may be compatible with tie systems having first and
second
structural members of various lengths and that form first intersection angles
X (See FIGS.
27-31) of 35, 37.5, and 45 degrees, respectively. Nonetheless, it is
understood that the
tie systems 200 can be shaped and scaled as necessary for implementation with
insulation layers of generally any size.
[00134] Once an appropriately sized tie system 200 is selected, the
tie
system 200 can be inserted the into an insulation layer. In some embodiments,
the tie
system 200 can be driven into the insulation layer by force. Such insertions
may be
facilitated by embodiments of the tie system 200 that include the teeth-like
elements 212
formed with the projection 208. Alternatively, or in conjunction, the
insulation layers can
be formed with pre-cut openings for installing the tie systems. As shown in
FIG. 32,
embodiments of the present invention provide for pre-cut openings in the form
of X-
shaped grooves 230 to be formed on the side edges of the insulation layers
240. It should
be understood that FIG. 32 illustrates a stack of multiple insulation layers
240, with each
of such insulation layers 240 each having a plurality of X-shaped grooves 230
formed
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along its side edge. The X-shaped grooves 230 can be sized and shaped so as to
receive
at least a portion of the projections 208 of the tie systems 200.
[00135] In some embodiments, as illustrated in FIG. 33, the X-shaped
grooves 230 can be formed with a hot-wire system 250 (e.g., a hot-wire harp)
comprising
a plurality of electrical wires 252 that cross each other so as present a
matrix of Xs when
the hot-wire system 250 is viewed from a front and/or rear elevation view. In
some
embodiments, the wires 252 of the hot-wire system 250 will be arranged in two
set apart
planes, with the wires 252 in a first plane being angled in a first direction
and the wires
252 in a second plane angle in a second direction. As such, the wires 252 that
cross each
other in the first and second directions can present the matrix of Xs. The hot-
wire system
250 is configured to provide electric current through each of the wires 252,
such that the
wires 252 will be heated to a temperature that is above a melting point of the
insulation
material of the insulation layers 240. As such, the wires 252 of the hot-wire
system 250
can be placed into contact with the side edges of one or more insulation
layers 240 so as
to melt a portion of the side edges to form the X-shaped grooves 230 in which
the tie
systems 200 can be inserted. It should be understood that although the
individual wires
252 of the hot-wire system 250 cross each other, the planes in which the wires
252 are
located are generally spaced apart such that the wires 252 do not come into
contact each
other so as to prevent the electrical current from "shorting out" between the
wires 252.
[00136] The number of insulation layers 240 which can be
simultaneously
processed to include the X-shaped grooves 230 is dependent on the size of the
insulation
layers 240 and on the dimensions of the hot-wire system 250. Nevertheless, the
hot-wire
system 250 is generally configured so as to be capable of simultaneously
processing
multiple insulation layers 240. Furthermore, the wires 252 of the hot-wire
system 250 can
be orientated so as to form X-shaped grooves 230 that presenting specific
intersection
angles. Such intersection angles may correspond with each of the first
intersection angles
X of the tie systems 200 (e.g., 35, 37.5, and 45 degrees). However, in some
embodiments, the wires 252 of the hot-wire system 250 can be orientated so as
to form
X-shaped grooves 230 that present other intersection angles. For instance, in
some
embodiments, the wires 252 of the hot wire system 250 may be configured to
create X-
shaped grooves 230 that present an intersection angle of 39.8 degrees. Such a
precise
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intersection angle may be used with insulation layers 240 having side edges of
about 8
feet in length. In such a configuration, exactly 20 X-shaped grooves 230 (each
being
about 4.8 inches in length) can be formed in the side edge of each of the
insulation layers
240.
[00137] Once the hot-wire system 250 is appropriately configured to
make X-
shaped grooves 230 in one or more insulation layers 240, the X-shaped grooves
230 can
be formed by holding the hot-wire system 250 stationary and moving a side edge
of the
insulation layers 240 into contact with the heated wires 252 of the hot-wire
system 252.
Alternatively, the insulation layers 240 can be held stationary and the hot-
wire system
250 can be moved into contact with the side edges of the insulation layers
240.
Regardless, the wires 252 of the hot-wire system 250 should be at least
partially
embedded into the side edges of the insulation layers 240 to a distance that
corresponds
with a size of the projections 208 of the tie systems 200 that are to be
inserted in the X-
shaped grooves 230. For instance, in embodiments in which the projections 208
of the
tie system 200 extend about 2 inches from the top portion 206, the X-shape
grooves 230
should be formed to correspondingly have a depth of about 2 inches.
[00138] Embodiments of the present invention may include a version of
the
hot-wire system 250 that only includes a single plane of wires 252. With
reference to FIG.
34, a single plane hot-wire system 260 is shown that includes only a single
plane of wires
252 that are angled only in a single direction. Such a hot-wire system 260 may
be used
so as to simplify the hot-wire system 250 and to reduce the possibility of
short circuiting
the wires 252. To create the X-shaped grooves 230 with the single plane hot-
wire system
260, the heated wires 252 can be made to contact a side edge of one or more
insulation
layers 240, via a first side of the single plane hot wire system 260, so as to
form a first
portion of the X-shaped grooves 230. Next, the insulation layers 240 can be
moved to the
opposite, second side of the single plane hot-wire system 260 and the heated
wires can
be made to again contact the side edge of the insulation layers 240 so as to
form a second
portion of the X-shaped grooves 230. Alternatively, the insulation layers 240
can remain
stationary, and after initially contacting the side edge of the insulation
layers 240, the
single plane hot-wire system 260 can be flipped and again be caused to contact
the side
edge of the insulation layers 240 so as form the X-shaped grooves 230. In even
further
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alternatives, two separate single plane hot-wire systems 260 can be used,
including a
first system 260 having a single plane of wires 252 extending in a first
angled direction
and a second system 260 having a single plane of wires 252 extending in a
second angled
direction. As such, a side edge of one or more insulation layers 240 can be
brought into
successive contact with each of the first and second single plane hot-wire
systems 260
so as to form the X-shaped grooves 230.
[00139] In addition to the hot-wire systems 250, 260 discussed above,
some
embodiments of the present invention additionally include a tie-positioning
template 270
that facilitates creation of the X-shaped grooves 230 in the side edges of the
insulation
layers 240. With reference to FIG. 35, such a tie-positioning template 270
includes an
elongated, U-shaped piece of material having a top section 272 and two side
sections
274 extending down from edges of the top section 272. The tie-positioning
template 270
additionally includes two elongated apertures 276 extending across the top
section 272
and extending down at least a portion of the side sections 274. The two
elongated
apertures 276 are generally angled, such that they intersect each other at an
intersection
point that lies at a midpoint of a width of the top section 272. Furthermore,
the elongated
apertures 276 should be orientated such that they correspond with the
orientation of the
projections 208 of one or more of the tie systems 200. For instance, the
elongated
apertures 276 may intersect to form a first intersection angle A and second
intersection
angle B that correspond with intersection angles X and Y, respectively
presented by the
tie systems 200. For example, the elongated apertures 276 may intersect to
form a first
intersection angle A of about 35, 37.5, or 45 degrees, which corresponds with
the first
intersection angles X of the tie systems 200 illustrated in FIGS. 27-31.
[00140] With reference to FIG. 36, the tie-positioning template 270
may be
constructed of generally any type of solid material, such as wood, metal,
polymers, or the
like. Furthermore, the tie-positioning template 270 should be sized so as to
fit snuggly
over a side edge of an insulation layer 240. For example, for an insulation
layer 240
having a thickness of 4 inches, a width of the top section 272 of the tie
positioning
template 270 (which also corresponds to the distance separating the two side
sections
274) should be approximately 4 inches. As such, the tie-positioning template
270 should
be operable to fit onto a portion of the side edge of the insulation layer 240
such that the
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top section 272 of the tie-positioning template 270 lies substantially flat
against the side
edge of the insulation layer 240 and the two side sections 274 extend partway
down the
adjacent surfaces of the insulation layer 240 (See FIG. 36). As such, a center
of the tie-
positioning template 270 is aligned with a midpoint of the side edge, i.e.,
centered on the
thickness of the insulation layer 240. With the tie-positioning template 270
properly
positioned on the insulation layer 240, such as illustrated in FIG. 36, a
panel maker can
cut an X-shaped groove 230 into the insulation layer 240 by forming cuts along
the
elongated apertures 276. The resulting X-shaped groove 230 (See FIG. 37) can
be
formed by the use of hand-tools, such as knives, handsaws, or the like, or
alternatively,
by the use of power-tools, such as skill-saws, jig-saws, reciprocating saws,
or the like.
[00141] Regardless of whether the X-shaped grooves 230 were formed
with
the hot-wire systems 250, 260 or with the tie-positioning template 270, after
the X-shaped
grooves are formed on an insulation layer 240, one or more tie systems 200 can
be
properly aligned within the insulation layer 240 by positioning the
projections 208 of the
tie systems 200 within the X-shaped grooves 230. With the tie systems 200
properly
positioned on the insulation layer 240, pressure is applied against the top
sections 206 of
the tie systems 200. As such, the projections 208 of the tie systems 200 will
be forced
into the X-shape grooves 230 of the insulation layer 240, thereby driving the
tie systems
into the insulation layer 240, such as shown in FIGS. 38 and 39. Embodiments
of the
present invention that include the projections 208 having a sharpened edge
and/or the
teeth-like elements 212 will facilitate the ability of the tie systems 200 to
be driven into the
insulation layer 240. In some instances, in may be necessary to drive the tie
systems 200
into the insulation layer 240 by striking the top sections 206 of the tie
systems 200 with a
hammer or mallet. In some embodiments, the process of driving in the tie
system 200 into
the insulation layer will form the X-shaped groove 230 into the side edge of
the insulation
layer. Regardless of the method used to drive the tie systems 200 into the
insulation layer
240, the tie systems 200 are driven into the insulation layer 240 until the
bottom surface
of the top section 206 is adjacent to the surface of the insulation layer 240.
As such, the
tie systems 200 are nearly flush with the side edge of the insulation layer
240.
[00142] In some alternative embodiments, a tie system 200 can be
inserted
within a side edge of an insulation layer 240 without first forming an X-
shaped groove
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230. Such insertions may be facilitated when using embodiments of the tie
system 200
that include the teeth-like elements 212 formed as part of the projection 208.
To begin, a
tie system 200 can be positioned on a side edge of the teeth-like elements 212
with the
projection 208 of the tie system 20 in contact with the insulation panel. The
tie system
should 200 be centered on the insulation layer 240, such that a center of the
tie system
200 is generally aligned with a midpoint of the thickness of the insulation
layer 240. In
embodiments of the tie system 200 that include the tabs 214, such as
illustrated in FIGS.
38-39, the tabs 214 can be positioned on either side of the insulation layer
240. For
example, for an insulation layer 240 having a thickness of 4 inches, a tie
system 200
having tabs 214 separated by distance D of 4 inches may preferably be used.
With the
tie system 200 centered, a portion of the first and second structural members
202, 204,
including the ends thereof, will overhang the side edge of the insulation
layer 240. As
such, the tie system 200 will be centered on the side edge such that the tie
system 200
can be properly inserted into the insulation layer 240. Upon insertion of one
or more tie
systems 200 into the side edge of one or more insulation layers 240, the
insulation layers
240 can be immediately used to create an insulated concrete panel.
[00143] Alternatively, as illustrated in FIG. 40, the insulation
layers 240 can
be pre-inserted with tie systems 200 and stacked for storage, for shipping,
and/or for
future use. For instance, certain construction jobsites may require insulation
layers 240
of particular sizes and/or may require tie systems 200 to be inserted within
the insulation
layers 240 at specific spacing intervals. As an illustrative example, an
insulated concrete
panel for use at a jobsite may require the use of three adjacent insulation
layers 240,
including a center insulation layer 240 opposed by two end insulation layers
240. The
ends of the insulated concrete panel may require the use of four tie systems
200 to be
inserted on the outer side edges of the two end insulation layers 240, while
the center
insulation layer 240 may only require use of two or three tie systems on its
side edges
(i.e., positioned between the central insulation layer 240 and each of the two
end
insulation layers 240). Beneficially, embodiments of the present invention
provide for the
specific arrangement of insulation layers 240 and tie systems 200 to be pre-
made (i.e.,
tie systems 200 pre-inserted in the insulation layers 240) and shipped to the
jobsite. In
some embodiments, the insulation layers 240 and/or the tie systems 200 can be
color
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coded to ensure the correct installation arrangement of the insulated concrete
panel at
the jobsite. In addition to increasing efficiency of jobsite construction,
such pre-making of
insulation layers and tie systems 200 ensure that the tie systems 200 are
correctly
installed/orientated in the insulation layers 240.
[00144] With reference to FIG. 41, to create an insulated concrete
panel 280,
a first insulation layer 282 can be formed with a set of one or more tie
systems 200
integrated with its side edge, as was described above. For most insulated
concrete panel
280, tie systems 200 will be located throughout the panel insulated concrete
280
approximately every 3 to 20 square feet, every 5 to 15 square feet, or every 8
to 10 square
feet. In some cases of high loading the tie systems 200 will need to be
positioned closer
together. Typical insulated concrete panel 280 can include 10 to 100, 20 to
80, or 25 to
40 tie systems 200. The tie systems 200 can be aligned with the longitudinal
or transverse
direction or at any other angle as deemed necessary by the engineer. Next, a
second
insulation layer 284 may be positioned adjacent to the first insulation layer
282 and the
tie systems 200 secured thereto (See FIG. 41). Because of the size and shape
of the tie
systems 200, the adjacent first and second insulation layers 282, 284 may have
very
small gaps therebetween. Specifically, such gaps will be generally equal to or
less than
a thickness of the top section 206 of the tie system 200. Next, a second set
of one or
more tie systems 200 may be inserted within an opposite side edge of the
second
insulation layer 284, in the same manner as described above, so as to create
multiple
adjacent insulation layers, with each adjacent insulation layer opposing a set
of one or
more tie systems 200. Multiple adjacent insulation layers can, thus, be
arranged as such
so as to form a wall of insulation layers (e.g., insulation layers 282, 284),
with each
insulation layer having sets of one or more tie systems therebetween. In such
a
configuration, the wall of insulation layers (e.g., insulation layers 282,
284) can be
sandwiched between layers of concrete to form the insulated concrete panel
280, as
described in more detail below. The insulation layers used in the insulated
concrete panel
280 can be specifically formed in different sizes and shapes so as to conform
the specific
requirements of the insulated concrete panel 280 in which they will be used.
In some
embodiments, adjacent insulation layers may have different thicknesses, such
that the
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insulated concrete panels can likewise be formed with different thicknesses
and/or
shapes, as may be required.
[00145] After the tie systems 200 has been inserted into the adjacent
insulation layers (e.g., insulation layers 282, 284), the insulated concrete
panel 280 can
be made by forming concrete layers on opposite sides of the insulation layers
282, 284.
In more detail, to form the insulated concrete panel 280, a bottom layer of
concrete 286
is poured in a lower form. In some embodiments, the bottom layer of concrete
286 will
undergo vibration so as to ensure proper settling of the concrete. Following
pouring the
bottom layer of concrete 286, the insulation layers 282, 284 with the tie
systems 200
coupled thereto can be lowered into engagement with the bottom layer of
concrete 286.
The portions of the first and second structural members 202, 204 of the tie
systems 200
that overhang the insulation layers 282, 284, including the ends and any
associated flaps
216, become inserted into and embedded within the bottom layer of concrete
286.
Furthermore, pressure may be exerted on the insulation layers 282, 284 (such
as by
walking on the insulation layers 282, 284) so that the bottom surface of the
insulation
layers 282, 284 will be inserted at least partially within a top surface of
the bottom layer
of concrete 286. Reinforcement in the form of rebar, steel mesh, or prestress
strand may
also be located in the bottom layer of concrete 286 so as to provide
additional strength
and support for the insulated concrete panel 280. Subsequent to placing the
insulation
layers 282, 284 and the tie systems 200 on/in the bottom layer of concrete
286, a top
layer of concrete 288 can be poured on the opposite side of the insulation
layers 282,
284. In some embodiments, the bottom layer of concrete 286 will need to cure
for a
period of time, such as 3 hours, before the top layer of concrete 288 can be
poured. When
the top layer of concreted 288 is poured, the portions of the first and second
structural
members 202, 204 of the tie systems 200 that overhang the insulation panels
282, 284,
as well as the ends and any associated flaps 216, become embedded within the
top layer
of concrete 288.
[00146] Once the top and bottom layers of concrete 286, 288 have at
least
partially cured, the outside forms can be removed and the insulated concrete
panel 280
is ready to be lifted and or shipped to the jobsite for installation. The X-
shape of the tie
systems 200 allow for the tie systems 200 to effectively transfer shear forces
and
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restricting delamination forces between the first and second layers of
concrete 286, 288
without deforming the insulation layers 282, 284. In some embodiments, the tie
systems
200 will be configured to transfer bending moments between the concrete
layers. In
particular, the tie system 200 is configured to transfer at least 500 pounds,
at least 1,000
pounds, at least 2,000 pounds, at least 5,000 pounds, at least 10,000 pounds,
at least
15,000 pounds, or at least 20,000 pounds and/or between 500 to 20,000 pounds,
between 1,000 and 15,000 pounds, or between 2,000 and 10,000 pounds of shear
force
between the layers of concrete. In addition, the tie system 200 is configured
to resist at
least 500 pounds, at least 1,000 pounds, at least 2,000 pounds, or at least
4,000 pounds
and/or between 500 to 4,000 pounds or between 1,000 and 2,000 pounds of
delamination
force between the layers of concrete. In addition, the tie system 200 is
configured to
include a tensile strength of at least 10,000 psi, at least 20,000 psi, at
least 30,000 psi, at
least 40,000 psi, at least 50,000 psi, or at least 60,000 psi and/or between
10,000 and
60,000 psi, between 20,000 and 50,000 psi, or between 30,000 and 40,000 psi.
Furthermore, the tie system 200 is configured to include a tensile modulus of
at least 1
million psi, at least 2 million psi, at least 3 million psi, at least 5
million psi, at least 6 million
psi, or at least 8 million psi and/or between 1 to 8 million psi, between 2 to
6 million psi,
or between 3 and 5 million psi. Thus, the resulting insulated concrete panel
280 will
comprise composite panel. The tie systems 200 will also act as tension members
that will
prevent the two layers of concrete 286, 288 from delamination during lifting
and shipping.
Further, as mentioned, the final insulated concrete panel can be reinforced
with rebar,
steel mesh, post tension cables, prestresss strand, or a combination of
reinforcement as
needed by the particular job requirements.
[00147] Given the above, embodiments of the present invention provide
for
the use of molded and/or formed 3-dimensional tie systems (i.e., wall ties),
with cross-
section in a C-shape, T-shape, I-shape, or L-shape, so as to construct
insulated concrete
panels in which the layers of the panels act in a composite or semi-composite
fashion.
[00148] Having thus described various embodiments of the invention,
what
is claimed as new and desired to be protected by Letters Patent includes the
following.
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