Attachment element for use with concrete wall and method employing same

Abstract

An attachment element for use with a concrete wall construction that includes a layer of concrete and a layer of an insulative material that is held against a face of the layer of concrete. The attachment element includes an elongated body member having a first portion that is adapted and arranged for embedment in the layer of concrete as the latter hardens and a second portion that is positioned longitudinally of the body member from the first portion. The second portion is adapted and arranged so as to extend outwardly from the face of the concrete and through a closed slot formed in the layer of insulative material. The attachment element also includes an elongated face plate that is attached to the second portion of the body member adjacent an outer end of the latter. The face plate is positioned so as to extend transversely of the body member and the same is adapted and arranged at the outer surface of the layer of insulative material in a position to extend laterally outwardly away from the body member and across the outer surface beyond the periphery of the slot. The entirety of the attachment element other than the face plate is small enough in size to permit insertion thereof through the slot during use.

I claim:  
     
         1 . An attachment element for use with a concrete wall construction that includes a layer of concrete and a layer of an insulative material that is held against a face of said layer of concrete, said layer of insulative material having an inner surface which is in contact with said face and an outer surface which is spaced from said face, the concrete of said layer thereof being characterized by having been initially fluid and having hardened with said face thereof in said contact with said inner surface of the layer of insulative material, said attachment element comprising: 
 an elongated body member having a first portion that is adapted and arranged for embedment in said layer of concrete as the latter hardens and a second portion positioned longitudinally of the body member from said first portion, said second portion being adapted and arranged so as to extend outwardly from said face and through a closed slot formed in said layer of insulative material, said slot having an outer periphery at said outer surface; and    an elongated face plate attached to said second portion adjacent an outer end of the latter, said face plate being positioned so as to extend transversely of said body member and being adapted and arranged at said outer surface of said layer of insulative material in a position to extend laterally outwardly away from said body member and across said outer surface beyond said periphery of said slot, the entirety of said attachment element other than said face plate being small enough in size to permit insertion thereof through said slot during use.    
     
     
         2 . An attachment element as set forth in  claim 1 , wherein said member and said plate are integrally connected.  
     
     
         3 . An attachment element as set forth in  claim 1 , wherein said portions of the body member are integrally connected.  
     
     
         4 . An attachment element as set forth in  claim 1 , wherein said element is monolithic.  
     
     
         5 . An attachment element as set forth in  claim 1 , wherein said element has a generally T-shaped transverse cross-sectional configuration.  
     
     
         6 . An attachment element as set forth in  claim 1 , wherein said face plate is formed from a material that is adapted for receiving and retaining a fastener.  
     
     
         7 . An attachment element as set forth in  claim 6 , wherein said material is a synthetic resin material.  
     
     
         8 . An attachment element as set forth in  claim 4 , wherein said element is formed from a material that is adapted for receiving and retaining a fastener.  
     
     
         9 . An attachment element as set forth in  claim 8 , wherein said material is a synthetic resin material.  
     
     
         10 . An attachment element as set forth in  claim 9 , wherein said material is an extendable thermoplastic material.  
     
     
         11 . An attachment element as set forth in  claim 7 , wherein said material is an extrudable thermoplastic material.  
     
     
         12 . An attachment element as set forth in  claim 1 , wherein said second portion of the body member is in the form of a sheet having opposed surfaces.  
     
     
         13 . An attachment element as set forth in  claim 12 , wherein said sheet is generally planar in configuration.  
     
     
         14 . An attachment element as set forth in  claim 12 , wherein is included one or more ribs which protrude laterally outwardly from a surface of said sheet.  
     
     
         15 . An attachment element as set forth in  claim 14 , wherein said ribs have generally rounded outer surfaces.  
     
     
         16 . An attachment element as set forth in  claim 1 , wherein said second portion includes an anchor segment located at the face of the concrete layer, said anchor segment being adapted and configured to retain said second portion in said concrete.  
     
     
         17 . An attachment element as set forth in  claim 12 , wherein said second portion includes an anchor segment located at the face of the concrete layer, said anchor segment being adapted and configured to retain said second portion in said concrete.  
     
     
         18 . An attachment element as set forth in  claim 17 , wherein said anchor segment includes a wing which extends laterally outwardly from a surface of the sheet.  
     
     
         19 . An attachment element as set forth in  claim 18 , wherein said wing includes a beveled surface at an outer edge thereof which defines a dovetail permitting the wing to be embedded in the layer of concrete during construction.  
     
     
         20 . An attachment element as set forth in  claim 14 , wherein said second portion includes an anchor segment located at the face of the concrete layer, said anchor segment being adapted and configured to retain said second portion in said concrete.  
     
     
         21 . An attachment element as set forth in  claim 20 , wherein said anchor segment includes a wing which extends laterally outwardly from a surface of the sheet.  
     
     
         22 . An attachment element as set forth in  claim 21 , wherein said wing includes a beveled surface at an outer edge thereof which defines a dovetail permitting the wing to be embedded in the layer of concrete during construction.  
     
     
         23 . A concrete wall structure comprising: 
 a layer of concrete having a face;    a layer of an insulative material that is retained against the layer of concrete, said layer of insulative material having an inner surface which faces the face of said layer of concrete and an outer surface that is spaced from the concrete layer, there being at least one closed slot extending through the thickness of the layer of insulative material from the inner surface to the outer surface, said slot having an outer periphery at said outer surface; and    an attachment element as set forth in  claim 1 , said first portion of the body member being embedded in said layer of concrete, said second portion of the body member protruding outwardly of the layer of concrete from said face and through said slot, and said elongated face plate extending transversely of said body member across the outer surface of the layer of insulative material.    
     
     
         24 . A concrete wall structure as set forth in  claim 23 , wherein said layer of insulative material comprises at least one panel having opposed side edges and opposed top and bottom edges, and said slot is positioned in spaced relationship relative to said edges.  
     
     
         25 . A concrete wall structure as set forth in  claim 24 , including a material applied against said outer face of the panel of insulative material and secured thereto at least in part by a fastener extending into the face plate.  
     
     
         26 . A method of constructing an insulated concrete wall structure comprising: 
 providing an attachment element as set forth in  claim 1;     forming at least one slot in a panel of insulative material having opposed first and second surfaces, said slot extending through said panel between said surfaces;    inserting the body member of the element through said slot so that the first portion extends outwardly a preselected distance from the first surface of the panel of insulative material and the face place is against the second surface of the panel of insulative material;    applying a layer of fluid concrete against said first surface in a position where the first portion of body member is surrounded by the fluid concrete;    allowing the concrete to set to thereby form an insulated concrete wall structure in which the first surface of the panel of insulative material is against the concrete, the first portion of the body member of the attachment element is embedded in the hardened concrete, the second portion of the body member of the attachment element extends through the slot, and the face plate of the attachment element extends across the second face of the panel of insulative material.    
     
     
         27 . A method as set forth in  claim 26 , including securing a finishing and/or decorative material to said wall structure by extending a fastener through said finishing and/or decorative material and into the face plate of the attachment element.  
     
     
         28 . A method as set forth in  claim 26 , wherein the insulative material is heat formable and said forming the slot comprises applying heat to the insulative material.  
     
     
         29 . A method as set forth in  claim 26 , including forming a plurality of said slots in said panel and positioning one of said attachment elements in each of said slots prior to the application of said layer of fluid concrete.