EP4551830A1

EP4551830A1 - A rod connector

Info

Publication number: EP4551830A1
Application number: EP23739202.2A
Authority: EP
Inventors: Henrik Pommergaard HANSEN
Original assignee: Dansk Byggekomponent Aps
Current assignee: Dansk Byggekomponent Aps
Priority date: 2022-07-05
Filing date: 2023-07-04
Publication date: 2025-05-14
Also published as: WO2024008746A1

Abstract

The present invention relates to a rod connector (1) for connecting and binding together a cast or molded layer of material to one or more additional layers of materials, comprising a threaded portion (2) comprising a cutting thread for screwing the rod connector into the one or more additional layers of materials in a longitudinal axis direction of the rod connector and optionally binding the one or more additional layers of materials together; and a head portion (5) arranged opposite the threaded portion, comprising one or more protrusions (6) extending substantially perpendicularly or near-perpendicularly to the longitudinal axis direction of the rod connector whereby the one or more protrusions of the head portion is/are configured to function as a male or female connector head for adaptation into a tool so that the rod connector can be screwed into the one or more additional layers of materials and subsequently be embedded into the cast layer.

Description

A rod connector

Technical Field

[0001] The present invention relates to a rod connector for connecting and binding together a cast or molded layer of material to one or more additional layers of materials.

Background

[0002] Reduction of energy consumption is important for minimizing the energy used for instance for heating a building or facility. Buildings or facilities are normally isolated for minimizing potential thermal losses between the interior or a building or facility and the surroundings, including the ground terrain.

[0003] Many buildings or facilities have a concrete deck opposite the ground terrain. Between the concrete deck and the ground terrain an insulation is usually arranged for minimizing the energy loss from the building to the surrounding terrain. However, sometimes the ground terrain can settle beneath the deck after it has been cast causing the insulation to separate from contact to the concrete deck. This separation a space between the insulation and the concrete deck occurs and in this space air and/or water may enter causing a thermal brigde between the construction parts which again inceases the energy consumption for heating up the building or facility.

[0004] In the art FR2553836A1 relates to a connector rod for binding roof tiles or a concrede deck to and underlying beam. KR20010039325 relates to a threaded foundation pillar for screwing into the ground employing a connector head. KR101133455 also to a threaded foundation pillar for screwing into the ground employing a connector head. KR20100009868 shows a threaded rod connectable to another threaded or unthreaded rod. None of these art are however suitable for binding together a cast or molded layer with one or more additional layers and offer the same advantages as the invention described herein.

Summary

[0005] The present invention provides improvements offering solutions to certain drawbacks of the background art including but not limited to the energy reducing steps especially for buildings or facilities. The present invention provides inter alia a rod connector configured to connecting and binding together a cast or molded layer of material to one or more additional layers of materials so that it securs that the layers of materials maintain its properties and functions independently of exterior factors, such terrain settling etc. Hence, the present invention provides an easy solution to mounting a rod connector to the one or additional layers of material before the cast layer is casted above the additional layers of material.

[0006] Accordingly, in an aspect the invention provides a rod connector for connecting and binding together a cast or molded layer (15) of material to one or more additional layers of materials (12) layer, comprising: an un-threaded shaft portion (la); a treaded portion (2) comprising a cutting thread (3) for screwing the rod connector (1) into the one or more additional layers (12) of materials in a longitudinal axis direction (4) of the rod connector and optionally binding the one or more additional layers of materials (12) together; and a head portion (5) arranged opposite the threaded portion, comprising one or more protrusions (6) extending substantially perpendicularly or near-perpendicularly to the longitudinal axis direction (4) of the rod connector (1) whereby the one or more protrusions (6) of the head portion (5) is/are configured to function as a male or female connector head (7) for adaptation into into a tool (18) so that the rod connector (1) can be screwed into the one or more additional layers of materials (12) and subsequently function also as achors when embedded into the cast layer (15).

[0007] In an additional aspect, the invention provides a connector system comprising the rod connector as described above connecting a layer of a cast or molded layer of material to one or more additional layers of materials.

[0008] In a further aspect the invention provides a tool for mounting or screwing the rod connector as described above into the the one or more additional layers, comprising in a connecting end a female tool socket configured to receiving the male or female connector head in a male-female configuration. [0009] In a still further aspect, the invention provides an assembly comprising the rod connector as described above connected to the tool as described above.

[0010] In an aspect of the invention a method for binding a cast or molded layer of material to one or more additional layers of materials is provided, the method comprising screwing the rod connector as described above into the one or more additional layers of materials, optionally using the tool as described above, so that the head portion extends from the one or more additional layers of materials, and then casting the layer of material so that it embeds the one or more protrusions of the head portion, and allowing the cast layer of material to solidify around the one or more protrusions of the head portion whereby the cast layer becomes bound to the one or more additiona layers of material. [0011] In a further aspect, the invention provides a method of producing the rod connector as described above or the tool as described above, comprising providing a synthetic polymer optionally reinforced by inorganic fibres and injecting the synthetic polymer into a mould having the form of the rod connector or screwing tool and releasing the rod connector or screwing tool from the mould. [0012] In an additional aspect, the invention provides a building or facility comprising a connector system as described above.

Brief description of drawings and figures

[0013] The figures included herein are illustrative and simplified for clarity, and they merely show details which are essential to the understanding of the invention, while other details may have been left out. Throughout the specification, claims and drawings the same reference numerals are used for identical or corresponding parts. In the figures and drawing include herein:

Figs, la-ld show a rod connector according to the invention in different views, including (lc) where a male connector head (7) including protrusions (6) extending substantially perpendicularly or near- perpendicularly to the longitudinal axis direction (4) of the rod connector are designed to engage into the female tool socket of a wrench tool or (Id) where the connector head (7) comprises an inner polygonal connector opening in the longitudinal axis of the rod connector designed as a female socket for receiving a male polygonal (hexagonal) drill bit fitted to engage into the hexagonal female socket. Fig. 2a shows the rod connector according to the invention screwed into two additional layers of material,

Fig. 2b shows the rod connector according to the invention connecting and binding together a cast or molded layer of material to two additional layers of materials,

Figs. 3a-3c show a a wrench tool according to the invention, the wrench tool is configured to mounting the rod connector into the the one or more additional layers,

Fig. 4a shows an assembly according of the invention, the assembly comprising the rod connector connected with the wrench tool,

Fig. 4b shows an enlarged view of the wrench tool connected with the male connector head of the head portion, and

Fig. 5 shows a cross-sectional view of a building having a pluralty of the connector rod of the invention. Fig. 6 shows the rod connector according to the invention in different views, where A represents the rod connector total length; B represents the width/diameter of stopper flange at cutouts, C represents the diameter of unthreaded portion of rod connector; D represents the length of threaded portion; E represents the diameter of threading; F represents the diameter of the stopper flange; G represents the width of head portion/male connector head including protrusions; H represents the diameter of protrusion; I is intentionally left out; J represents the depth of the threading; and K represents the threading pitch.

Incorporation by reference [0014] All publications, patents, and patent applications referred to herein are incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference. In the event of a conflict between a term herein and a term in an incorporated reference, the term herein prevails and controls.

Detailed Description

[0015] The features and advantages of the present invention is readily apparent to a person skilled in the art by the below detailed description of embodiments and examples of the invention with reference to the figures and drawings included herein.

[0016] Figs, la and lb show in different side views a rod connector (1) according to the invention for connecting and binding together a cast or molded layer of material (not shown) to one or more additional layers of materials (not shown).

[0017] The rod connector comprises an un-threaded shaft portion which in some embodiments has a diameter (C) of between 2 mm to 20 mm, optionally between 5 mm to 15 mm, optionally between 9 mm to 11 mm.

[0018] In further embodiments the rod connector (1) comprises a treaded portion 2 comprising a cutting thread (3) for screwing the rod connector (1) into the one or more additional layers of materials in a longitudinal axis direction (4) of the rod connector (1) and optionally binding the one or more additional layers of materials together. In addition, the rod connector (1) comprises a head portion (5) arranged opposite the threaded portion (2). The head portion (5) comprises one or more protrusions (6) extending substantially perpendicularly or near-perpendicularly to the longitudinal axis direction (4) of the rod connector (1) whereby the one or more protrusions of the head portion (5) are configured to function as a male connector head (7) for adaptation into into a tool (not shown) so that the rod connector (1) can be screwed into the one or more additional layers of materials and subsequently be embedded into the cast layer. The tool will be described further in connection with Figs. 3a-3c below. In an alternative embodiment the connector head (7) comprises an inner polygonal connector opening in the longitudinal axis of the rod connector designed as a female socket for receiving a male polygonal (hexagonal) drill tool fitted to engage into the hexagonal female socket.

[0019] The cutting thread (3) may have a length (H in figure 6) in the longitudinal axis direction (4) of the rod connector (1) of at least 100 mm, such as from 100 mm to 110 mm, such as from 110 mm to 120 mm, such as from 120 mm to 130 mm, such as from 130 mm to 140 mm, such as from 140 mm to 150 mm, such as from 150 mm to 160 mm, such as from 160 mm to 170 mm, such as from 170 mm to 180 mm, such as from 180 mm to 190 mm, such as from 190 mm to 200 mm, such as from 200 mm to

250 mm, such as from 250 mm to 300 mm, such as from 300 mm to 350 mm, such as from 350 mm to

400 mm, such as from 450 mm to 500 mm. In some embodiments the length D is between 100 mm to

150 mm, such as between 125 mm to 135 mm, such as between 129 mm to 131 mm.

[0020] In further embodiments the cutting thread has a diameter (E in figure 6) between 10 mm to 100 mm, optionally between 15 mm to 50 mm, optionally between 20 mm to 30 mm, optionally between 24 mm to 26 mm.

[0021] In addition, the cutting thread (3) has a pitch, the pitch may be at least 15 mm, such as between 15 mm to 20 mm, such as between 20 mm to 25 mm, such as between 25 mm to 30 mm, such as between 30 mm to 35 mm, such as between 35 mm to 40 mm, such as between 40 mm to 45 mm, such as between 45 mm to 50 mm. In some embodiments the pitch (K of figure 6) is between 10 mm to 100 mm, optionally between 15 mm to 50 mm, optionally between 20 mm to 30 mm, optionally between 24 mm to 26 mm.

[0022] Also, the cutting thread (3) has a depth, the depth may be at least 2 mm, such as between 2 mm to 4 mm, such as between mm to 6 mm, such as between 6 mm to 8 mm, such as between 8 mm to 10 mm, such as between 10 mm to 2 mm, such as between 12 mm to 14 mm, such as between 14 mm to 16 mm, such as between 16 mm to 20 mm, such as between 20 mm to 25 mm, such as between 25 mm to 30 mm, such as between 30 mm to 40 mm, such as between 40 mm to 50 mm. In other embodiments the depth (J of figure 6) of the thread is from 2 mm to 50 mm, optionally between 5 mm to 20 mm, optionally between 6 mm to 10 mm, optionally between 7 mm to 8 mm. The pitch and depth of the threading is very important for ensuring the the rod connector when screwing it into the additional layers does not fluff or flange the materials and that the threading stays firmly embedded in the material. As demonstrated in figure 7 threading have a high theading depth and a low pitch created more fluffing /flanging of the layer material where the material is polystyrene.

[0023] The threaded portion (2) has a thread end (8), and in some embodiments the thread end is a tip (8) enabling that the rod connector may be screwed into the one or more additional layers. A threading tip helps controlling that the rod connector does not skid across the surface of the additional layer when screwing the rod connector into the additional layer(s).

[0024] Furthermore, the cutting thread (3) is elongated, so that it is capable of cutting through the one or more additional layers without fluffing the layer material, when screwed into the one or more additional layers.

[0025] As seen in Figs, la-lc, the one or more protrusions (6) are extending substantially perpendicularly or near-perpendicularly to the longitudinal axis direction (4) of the rod connector (1). Hereby is obtained that the protusions (6) firstly may engage a wrench tool whereby the connector rod (1) may be screwed into the one or more additional layers by means of the wrench tool. The protrusions are confirgured to mechanically engage a corresponding part of the wrench tool, in a so- called male-female connection, so that the mounting of the connector rod (1) is facilitated. After the connector rod (1) has been mounted in the one or more additional layers the protrusions (6) function as an anchor which are being embedded into the cast layer when it solidifies around the head portion of the connector rod (1). Hence, the connector rod (1) ensures that the one or more additional layers are connected binded together with the cast layer so that the risk for the one or more additional layers dislocate in relation the cast layer is minimised.

[0026] The protrusions (6) may be pin or cylinder formed and may have a cylindrical or polygonic shape. The pins may have a cross-sectional diameter d or diagonal of between 4 to 20 mm, such as between 4 mm to 6 mm, such as between 6 mm to 8 mm, such as between 8 mm to 10 mm, such as between 10 mm to 12 mm, such as between 12 mm to 14 mm, such as between 14 mm to 16 mm, such as between 16 mm to 20 mm. The protrusions preferably extend from between 4 mm to 20 mm from the rod connector axis, such as between 4 mm to 6 mm, such as between 6 mm to 8 mm, such as between 8 mm to 10 mm, such as between 10 mm to 12 mm, such as between 12 mm to 14 mm, such as between 14 mm to 16 mm, such as between 16 mm to 20 mm. In some embodiments pin or cylinder-shaped protrusions have a cross-sectional diameter or diagonal (D of figure 6) of between 4 mm to 10 mm, optionally between 6 mm to 10 mm, optionally between 7,5 mm to 8,5 mm. In further embodiments, the head portion (5) has a width (G of figure 6) including the protrusion(s) of between 10 mm to 50 mm, optionally between 20 mm to 40 mm, optionally between 30 mm to 35 mm.

[0027] As seen in Figs, la-lc the head portion (5) comprises at least two protrusions (6) oppositely positioned on the head portion (5). In addition, the head portion (5) may comprise at least two protrusions (6) distanced with at least 10 mm in the longitudinal axis direction (4) of the rod connector (1). In the shown embodiment, the head portion (5) comprises at least four protrusions (6), optionally exactly 4 protrusions, pairwise oppositely positioned on the head portion (5) and wherein the pairs are distanced with at least 10 mm in the longitudinal axis direction (4) of the rod connector (1). Optionally, a plurality of protrusions (6) may be arranged on the head portion (5). Furthermore, the pairwise oppositely positioned protrusions (6) may be aligned, so that one protrusion of the first pair is positioned in parallel to a protrusion of the second pair in the longitudinal axis direction (4) of the rod connector (1). In another not shown embodiment, the pairwise oppositely positioned protrusions (6) may be disaligned. One advantage of employing multiple protrusions which are spatially distributed on the head portion along the axis of the rod connector is is ensures a better embedding in the casting layer even in case of casting voids around the rod connector. Hereby it is ensured that the head portion may be anchored properly to cast layer after it solidify, whereby the rod connector (1) maintain the additional layers to the cast layer in the longitudinal axis direction of the rod connector independently of any movements or the terrain below the additional layers of material.

[0028] The connector rod (1) may also comprise a stopper portion 10 arranged between the threaded portion (2) and the head portion (5), which when in contact with the one or more additional layers, stops the threaded portion (2) from penetrading further into the one or more additional layers. The stopper portion 10 may comprise a flange (11) circumferentially encircling the longitudinal axis (4) of the rod connector (1) and optionally have a disc or circular shape. In addition, the flange (11) may have a diameter of at least 20 mm such as between 20 mm to 25 mm, such as between 25 mm to 30 mm, such as between 30 mm to 35 mm, such as between 35 mm to 40 mm such as between 40 mm to 45 mm, such as between 45 mm to 50 mm. In further embodiments the flange has diameter (F of figure 6) from 10 mm to 50 mm, optionally between 25 mm to 45 mm, optionally between 34 mm to 36 mm. [0029] The flange may have thickness of at least 2mm. In other embodiments the flange has a thickness between 1 mm to 5 mm.

[0030] IN further embodiments the flange comprises one or more cutouts (11a) matching to a tool, optionally a wrench, configured for turning and tightening the rod connector into the additional layers. Such cutouts are useful where the wrench tool for screwing the rod connector into the additional lis insufficient and it is needed to finally tighten the rod connector into the additional layers, suitably using a spanner, fixed or adjustable wrench. In further embodiments the cutouts are linear and parallel and positioned oppositedly at the edge/circumference of the flange and the flange diamether between at the cutouts (B of figure 6) is between 10 mm to 40 mm, such as between 25 mm to 35 mm, such as between 31 mm to 33 mm.

[0031] The flange (11) may be positioned at least 10 mm from promixal most protrusion (6) of the head portion (5). Also, the flange (11) may be positioned at least 90 mm from the promixal-most part of cutting thread (3).

[0032] The connector rod (1) may have a total length of at least 300 mm, such as between 300mm to 325 mm, such as between 325 mm to 350 mm, such as between 350 mm to 375 mm, such as between 375 mm to 400 mm, such as between 400 mm to 450 mm, such as between 450 mm to 500 mm, such as between 500 mm to 550 mm, such as between 550 mm to 600 mm. In a preferred embodiment the total length (A of figure 6) of the rod connector is between 380 mm to 390 mm, such as between 385 mm to 386 mm, which is particularly useful for binding together two plates of polystyrene insulation plates of each 200 mm. In addition, the un-threaded shaft portion of the rod connector (1) may have a cylinder or near-cylinder shape having a diameter of between 5 mm to 20 mm, such as between 5 mm to 8 mm such as between 8 mm to 12 mm. such as between 12 mm to 15 mm. such as between 15 mm to 20 mm. such as between 20 mm to 30 mm. In some embodiment the diameter of the un- threaded shaft portion is between 9 mm to 11 mm.

[0033] The rod connector (1) may be made of a synthetic polymer optionally reinforced by inorganic fibres. The synthetic polymer may be selected from polyamide (nylon) 66, Polyamide (nylon) 6, polypropylene or polyethylene or a combination thereof and wherein the inorganic fibres are selected from glass fibres or any composites thereof.

[0034] In a separate aspect also described herein is a rod connector as described in any of the preceding embodiments, but where the head portion only include a female connector head (7) for adaptation into into a tool (18) so that the rod connector (1) can be screwed into the one or more additional layers of materials (12), and so that the head portion does not contain a part having protrusions for embedding into the the cast or molded layer.

[0035] In Fig. 2a a cross-sectional view is shown wherein the connector rod (1) according to the invention is mounted into two layers (12) so that the stopper portion 10 abuts a top face of the layer 12 and prevents the connector rod (1) in being screwed further into the layers (12). Hereby it is ensured that the head portion (5) is positioned a distance above the top face (13) of the layer (12).

[0036] In further embodiments the connector head (7) comprises an inner polygonal connector opening in the longitudinal axis of the rod connector designed as a female socket for receiving a male polygonal (hexagonal) drill bit fitted to engage into the polygonal female socket.

[0037] In further embodiments the rod connector is a rod connector wherein the total lentgh (A) is between 385 mm to 386 mm; wherein the diameter (C) of the un-threaded shaft portion is between 9 mm to 11 mm; wherein the head portion have four cylinder formed protrusions pairwise oppositely positioned and aligned so that the first protrusion of the first pair is positioned in parallel to the first protrusion of the second pair in the longitudinal axis direction of the rod connector, wherein the diameter (D) of the protrusions are between 7 mm to 8 mm, and wherein the diameter of the head portion including the protrusions (G) is between 34 mm to 36 mm; wherein the rod connector comprises a circular shaped flange stopper portion having a diameter (F) between 34 mm to 36 mm, said flange comprising two parallel linear cutouts having a diameter (B) between the cutouts is between 31 mm to 33 mm; wherein the threaded portion has (i) a length (H) between 129 mm to 130 mm, (ii) a diameter (E) between 24 mm to 26 mm, (iii) a theading pitch (K) between 26 mm to 27 mm, and (iv) a threading depth (J) between 7 mm to 8 mm.

[0038] Fig. 2b shows a cross-sectional view of a connector system (14) comprising the rod connector (1) as described herein connecting a layer of a cast or molded layer (15) of material to one or more additional layers (12) of materials.

[0039] The cast layer (15) is a concrete layer comprising mineral particles and cement, and/or reinforcement (16), and optionally has a layer thickness of at least 50 mm. The cast layer (15) may comprise one or more layers of concrete or other similar materials. The one or more additional layers (12) of materials comprises a thermally, electrically and/or hydrodynamically insulating material, optionally comprising a synthetic foam, such as a polystyrene foam or a mineral wool, such as rock or glass wool. In the present embodiment, the connector system (14) comprises two additional layers (12). In other embodiments another number of layers may be chosed according to the specific requirements. Also, only one layer may be present. In some embodiments the system comprises two or more additional layers (12), bound together by the connector rod and further the additional layers are in contact with each other, and at least one of the layers is in contact with the cast or molded layer.

[0040] The one or more additional layers (12) may have a thickness of at least 400 mm and wherein optionally the cutting tread of the rod connector (1) penetrates through the one or more additional layers (12), optionally by at least 10 mm. In some embodiment the additional layers comprise 2 layers of mineral wool and/or styroform foam having a thickness of 200 mm each. Furthermore, the cast layer (15) may be a concrete ground deck of a building and the one or more additional layers (12) are insulation plates below the ground deck. In an embodiment, a membrane may be arranged between the cast layer and the one or more additional layers. The membrane may for instance be a radon preventing folio or membrane. Membranes having other properties and requirements may also be arranged in the connector system (14). In addition, tubes, or hoses 17 may be arranged in the cast layer (15) to, for instance, a fluid underfloor heating system.

[0041] Figs. 3a to 3c show a tool 18 for mounting the rod connector (1) into the the one or more additional layers (12). The tool 18 comprises, in a connecting end 19, a female tool socket 20 configured to receiving the male connector head (7) of the connector rod (1) in a male-female configuration so that the protrusions (6) of the male connector head (7) mechanically engage the female tool socket (20). Hereby it is possible to rotate the connector rod (1) by transferring rotation of the tool (18) via the male-female connection. The female tool socket (20) comprising at least one slit (21) in a longitudinal tool axis (22) of the tool (18), receiving the at least one protrusion (6) of the rod connector (1) and allowing the female tool socket (20) to receive the male connector head (7). In addition, two oppositely positioned slits may be arranged being configured to receive two oppositely positioned protrusions (6) on the male connector head (7). The slit(s) (21) further comprises bend(s) (23) perpendicular or near perpendicular to the longitudinal tool axis (22) of the tool (18), allowing the tool socket (20) to lock the male connector head (7) by sliding the at least one protrusion (6) into the slit bend (23) and twisting the tool (18). The tool (18) also comprises, in a tool end (24), arranged opposite the connecting end (19), a polygonal head (25) for insertion into a screwing device, optionally a drill bit on an electric screwdriver. The polygonal head (25) may be a hexagonal head. Also, the polygonal head (25) may have a head length of at least 40 mm and a longest diameter or diameter of at least 10 mm. The tool (18) may have a total length, sufficuient for a worker standing upright on the one or more additional layers of materials to mount the rod connector (1) connected to the tool (18) into the one or more additional layers of materials in an ergonomic working position. In an embodiment, the total length of the tool (18) is at least 400 mm. In an alternative embodiment the connecting end (19) of the tool comprises a male polygonal (hexagonal or octagonal) head for engaging into a matching inner polygonal connector opening in the longitudinal axis of the rod connector designed as a female socket for receiving a male polygonal end (19). The longest diagonal or diameter of the polygonal opening is preferably at least 5 mm, such as between 5 mm to 7 mm, such as between 7 mm to 9 mm, such as between 9 mm to 11 mm, such as between 11 mm to 13 mm, such as between 13 mm to 15 mm, such as between 15 mm to 20 mm.

[0042] In Fig. 4a an assembly (30) comprising the rod connector (1) connected with the tool (18) is shown. Fig. 4b shows an enlarged view of an embodiment of a connection between the connector rod (1) and the tool (18). In present embodiment the protrusions (6) of the male connector head (7) of the head portion (5) of the connector rod (1) are engaging the slit bends (23) of the female socket (20) of the tool (18) so that by rotating the tool (18) the rotation is transferred to the connector rod (1) via the connection.

[0043] In Fig. 5 a building (100) is shown in a cross-sectional view. The building (100) comprises the system (14) according to the invention. The system (14) comprising a plurality of rod connectors 1 connecting a layer of a cast or layer (15) molded layer (15) of material to one or more additional layers (12) of materials. In the present embodiment the the cast layer (15) is a concrete ground deck of the building (100) and the one or more additional layers (12) are insulation plated below the ground deck. [0044] The invention also relates to a method for binding a cast or layer (15)molded layer (15) of material to one or more additional layers (12) of materials, thereby producing a system described herein, said method comprising screwing the rod connector (1) as described above into the one or more additional layers (12) of materials, optionally using the tool (18) as described above, so that the head portion (5) of the connector rod (1) extends from the one or more additional layers (12) of materials, and then casting the cast layer (15) of material so that it embeds the one or more protrusions (6) of the head portion (5), and allowing the cast layer (15) of material to solidify around the one or more protrusions (6) of the head portion (5) whereby the cast layer (15) becomes bound to the one or more additional layers (12) of material. In addition, a reinforcement may be arranged above the one or more additional layers (12) of materials either before screwing the connector rod (1) into the one or more additional layers (12), or after the connector rod (1) has been screwed into the one or more additional layers (12). Furthermore, a membrane may be arranged above the one or more additional layers (12) before the connector rod (1) is screwed through the membrane and into the one or more additional layers (12).

[0045] Additionally, the invention relates to a method of producing the rod connector (1) as described above or the tool (18) as described above, comprising providing a synthetic polymer optionally reinforced by inorganic fibres and injecting the synthetic polymer into a mould having the form of the rod connector (1) or tool (18) and releasing the rod connector (1) or tool (18) from the mould.

References

1 Rod connector la Un-threaded shaft portion

2 Threaded portion

3 Cutting thread

4 Longitudinal axis direction

5 Head portion

6 Protrusions

7 Connector head

7a Inner polygonal connector opening

8 Threaded end/tip

9 Head end

10 Stopper portion

11 Flange

11a Flange cutout

12 One or more additional layers

13 Top face

14 Connector system

15 Cast layer

16 Reinforcement

17 Hoses

18 Tool

19 Connecting end

20 Female tool socket

21 Slit

22 Longitudinal tool axis 23 Bend

24 Tool end

25 Polygonal head

30 Assembly

100 Building

Items of the invention

1. A rod connector (1) for connecting and binding together a cast or molded layer (15) of material to one or more additional layers (12) of materials, comprising a treaded portion (2) comprising a cutting thread (3) for screwing the rod connector (1) into the one or more additional layers (12) of materials in a longitudinal axis direction (4) of the rod connector (1) and optionally binding the one or more additional layers (12) of materials together; and a head portion (5) arranged opposite the threaded portion, comprising one or more protrusions (6) extending substantially perpendicularly or near-perpendicularly to the longitudinal axis direction (4) of the rod connector whereby the one or more protrusions (6) of the head portion (5) is/are configured to function as a male or female connector head (7) for adaptation into into a tool (18) so that the rod connector (1) can be screwed into the one or more additional layers (12) of materials and subsequently be embedded into the cast layer (15).

2. The rod connector of item 1, wherein the cutting thread (3) is elongated, so that it is capable of cutting through the one or more additional layers (12) without fluffing, when screwed into the one or more additional layers.

3. The rod connector of any preceding items, wherein the cutting thread (3) has a length in the longitudinal axis direction (4) of the rod connector (1) of between 100 mm to 300 mm.

3. The rod connector of any preceding items, wherein a pitch of the cutting thread (3) is from 20 mm to 40 mm.

4. The rod connector of any preceding items, wherein a depth of the thread is from 2 mm to 50 mm.

5. The rod connector of any preceding items, wherein the threaded portion (2) has a thread end (8), the thread end is a tip. 6. The rod connector of any preceding items, wherein the protrusions (6) are pin formed and have a cylindrical or polygonic shape.

7. The rod connector of item 6, wherein the pins have a cross-sectional diameter or diagonal of between 4 to 10 mm.

8. The rod connector of any preceding items, wherein the head portion (5) comprises at least two protrusions (6) oppositely positioned on the head portion (5).

9. The rod connector of item 8, wherein the head portion (5) comprises at least two protrusions (6) distanced with at least 10 mm in the longitudinal axis direction (4) of the rod connector.

10. The rod connector of item 8 or 9, wherein the head portion (5) comprises at least four protrusions (6), pairwise oppositely positioned on the head portion and wherein the pairs are distanced with at least 10 mm in the longitudinal axis direction of the rod connector.

11. The rod connector of item 10, wherein the pairwise oppositely positioned protrusions (6) are aligned, so that one protrusion of the first pair is positioned in parallel to a protrusion of the second pair in the longitudinal axis direction of the rod connector.

12. The rod connector of items 9 to 11, wherein the distal most protrusion(s) are positioned between 0 mm to 50 mm from a head end (9).

13. The rod connector of items 10 to 12, wherein the proximal most protrusion(s) are positioned between 25 mm to 100 mm from the head end (9).

14. The rod connector of any preceding item, further comprising a stopper portion (10) arranged between the threaded portion (2) and the head portion (5), which when in contact with the one or more additional layers (12), stops the threaded portion (2) from penetrading further into the one or more additional layers.

15. The rod connector of item 14, wherein the stopper portion (10) comprise a flange (10) circumferentially encircling the longitudinal axis (4) of the rod connector and optionally have a disc shape. 16. The rod connector of item 15, wherein the flange has diameter of from 10 mm to 50 mm.

17. The rod connector of items 15 to 16, wherein the flange has thickness of at least 2mm.

18. The rod connector of items 15 to 17, wherein the flange is positioned at least 10 mm from promixal most protrusion of the head portion.

19. The rod connector of items 15 to 18, wherein the flange is positioned at least 90 mm from the promixal most part of the cutting thread (3).

20. The rod connector of any preceding item, having total length of between 200 mm to 500 mm.

21. The rod connector of any preceding item, having cylinder or near-cylinder shape having a diameter of between 8 mm to 20 mm.

22. The rod connector of any preceding item, wherein the rod connector is made of a synthetic polymer optionally reinforced by inorganic fibres.

23. The rod connector of item 22, wherein the synthetic polymer is selected from polyamide (nylon) 66, Polyamide (nylon) 6, polypropylene or polyethylene or a combination thereof and wherein the inorganic fibres are selected from glass fibres or any composites thereof.

24. A connector system (14) comprising the rod connector (1) of item 1 to 23 connecting a layer of a cast or molded layer (15) of material to one or more additional layers (12) of materials.

25. The system of item 24, wherein the cast layer (15) is a concrete layer comprising mineral particles and cement, and/or reinforcement, and optionally has a layer thickness of at least 50 mm.

26. The system of items 24 to 25, wherein the one or more additional layers (12) of materials comprises a thermally, electrically and/or hydrodynamically insulating material, optionally comprising a synthetic foam, such as a polystyrene foam or a mineral wool, such as rock or glass wool.

27. The system of claim 24 to 26, comprising two or more additional layers (12). 28. The system of item 24 to 1 , wherein the one or more additional layers (12) have a thickness of at least 400 mm and wherein optionally the cutting tread (3) of the rod connector (1) penetrates through the one or more additional layers (12), optionally by at least 10 mm.

29. The system of items 24 to 28, wherein the cast layer (15) is a concrete ground deck of a building, and the one or more additional layers (12) are insulation plated below the ground deck.

30. The system of items 24 to 29, wherein a membrane is arranged between the cast layer and the one or more additional layers.

31. A tool (18) for mounting the rod connector (1) of item 1 to 23 into the the one or more additional layers (12), comprising, in a connecting end (19), a female tool socket (20) configured to receiving the male connector head (7) in a male-female configuration.

32. The tool of item 31, comprising at least one slit (21) in a longitudinal tool axis (22) of the tool, receiving the at least one protrusion (6) of the rod connector and allowing the female tool socket (20) to receive the male connector head.

33. The tool of items 31 to 32, comprising at two oppositely positioned slits (21) receiving two oppositely positioned protrusions (6) of the male connector head.

34. The tool of items 31 to 33, wherein the slit(s) further comprises bend(s) (23) substantially perpendicular or near-perpendicular to the longitudinal tool axis (22) of the tool, allowing the tool socket to lock into the male connector head (7) by sliding the at least one protrusion (6) into the bend (23) and twisting the tool.

35. The tool of item 31 to 34, further comprising, in a tool end (24) arranged opposite the connecting end, a polygonal head (25) for insertion into a screwing device, optionally a drill bit on an electric screwdriver.

36. The tool of items 31 to 35, wherein the polygonal head is a hexagonal head.

37. The tool of items 31 to 36, wherein the polygonal head has a length of at least 40 mm and a longest diameter or diameter of at least 10 mm.

38. The tool of items 31 to 37, wherein the tool has a total length, sufficuient for a worker standing upright on the one or more additional layers of materials (300) to mount the rod connector connected to the tool into the one or more additional layers of materials in an ergonomic working position.

39. The tool of items 31 to 38, the total length of the tool is at least 400 mm.

40. An assembly (30) comprising the rod connector (1) of items 1 to 23 connected with the tool (18) of items 31 to 39.

41. A method for binding a cast or molded layer (15) of material to one or more additional layers (12) of materials, comprising screwing the rod connector (1) of items 1 to 23 into the one or more additional layers (12) of materials, optionally using the tool (18) of items 31 to 39, so that the head portion (5) extends from the one or more additional layers (12) of materials, and then casting the layer (15) of material so that it embeds the one or more protrusions (6) of the head portion (5), and allowing the cast layer (15) of material to solidify around the one or more protrusions (6) of the head portion whereby the cast layer (15) becomes bound to the one or more additiona layers (12) of material.

42. A method of producing the rod connector (1) of items 1 to 23 or the tool (18) of items 31 to 39, comprising providing a synthetic polymer optionally reinforced by inorganic fibres and injecting the synthetic polymer into a mould having the form of the rod connector or screwing tool and releasing the rod connector or screwing tool from the mould.

43. A building (100) or facility comprising a connector system (14) according to any of the items 24 to 30.

44. The rod connector of items 10 to 13, wherein the where the connector head (7) further comprises an inner polygonal connector opening in the longitudinal axis of the rod connector designed as a female socket for receiving a male polygonal (hexagonal) drill bit fitted to engage into the polygonal female socket.

Claims

1. A rod connector (1) for connecting and binding together a cast or molded layer (15) of material to one or more additional layers (12) of materials, comprising an un-threaded shaft portion (la); a threaded portion (2) comprising a cutting thread (3) for screwing the rod connector (1) into the one or more additional layers (12) of materials in a longitudinal axis direction (4) of the rod connector (1) and optionally binding the one or more additional layers (12) of materials together; and a head portion (5) arranged opposite the threaded portion, comprising one or more protrusions (6) extending substantially perpendicularly or near-perpendicularly to the longitudinal axis direction (4) of the rod connector whereby the one or more protrusions (6) of the head portion (5) is/are configured to function as a male or female connector head (7) for adaptation into into a tool (18) so that the rod connector (1) can be screwed into the one or more additional layers (12) of materials and subsequently be embedded into the cast layer (15).

2. The rod connector of any preceding claims, wherein the un-threaded shaft portion has a diameter (C) of between 2 mm to 20 mm, optionally between 5 mm to 15 mm, optionally between 9 mm to 11 mm.

3. The rod connector of any preceding claim, wherein the cutting thread (3) is elongated, so that it is capable of cutting through the one or more additional layers (12) without fluffing, when screwed into the one or more additional layers.

4. The rod connector of any preceding claims, wherein the cutting thread (3) has a length (H) in the longitudinal axis direction (4) of the rod connector (1) of between 100 mm to 300 mm, optionally between 100 mm to 150 mm, such as between 125 mm to 135 mm, such as between 129 mm to 131 mm.

5. The rod connector of any preceding claims, wherein the cutting thread (3) has a diameter (E) between 10 mm to 100 mm, optionally between 15 mm to 50 mm, optionally between 20 mm to 30 mm, optionally between 24 mm to 26 mm.

6. The rod connector of any preceding claims, wherein a pitch (K) of the cutting thread (3) between 10 mm to 100 mm, optionally between 15 mm to 50 mm, optionally between 20 mm to 30 mm, optionally between 24 mm to 26 mm

7. The rod connector of any preceding claims, wherein a depth (J) of the thread is from 2 mm to 50 mm, optionally between 5 mm to 20 mm, optionally between 6 mm to 10 mm, optionally between 7 mm to 8 mm.

8. The rod connector of any preceding claims, wherein the threaded portion (2) has a thread end (8), wherein optionally the thread end is a tip.

9. The rod connector of any preceding claims, wherein the protrusions (6) are pin or cylinder formed and have a cylindrical or polygonic shape.

10. The rod connector of claim 9, wherein the pins have a cross-sectional diameter or diagonal (D) of between 4 mm to 10 mm, optionally between 6 mm to 10 mm, optionally between 7,5 mm to 8,5 mm.

11. The rod connector of any preceding claim, wherein the head portion has a width (G) including the protrusion(s) of between 10 mm to 50 mm, optionally between 20 mm to 40 mm, optionally between 30 mm to 35 mm.

12. The rod connector of any preceding claims, wherein the head portion (5) comprises at least two protrusions (6) oppositely positioned on the head portion (5).

13. The rod connector of claim 12, wherein the head portion (5) comprises at least two protrusions (6) distanced with at least 10 mm in the longitudinal axis direction (4) of the rod connector.

14. The rod connector of claim 12 or 13, wherein the head portion (5) comprises at least four protrusions (6) , optionally exactly 4 protrusions, pairwise oppositely positioned on the head portion and wherein the pairs are distanced with at least 10 mm in the longitudinal axis direction of the rod connector.

15. The rod connector of claim 14, wherein the pairwise oppositely positioned protrusions (6) are aligned, so that one protrusion of the first pair is positioned in parallel to a protrusion of the second pair in the longitudinal axis direction of the rod connector.

16. The rod connector of claims 12 to 15, wherein the distal most protrusion(s) are positioned between 0 mm to 50 mm from a head end (9).

17. The rod connector of claims 14 to 16, wherein the proximal most protrusion(s) are positioned between 25 mm to 100 mm from the head end (9).

18. The rod connector of any preceding claim, further comprising a stopper portion (10) arranged between the threaded portion (2) and the head portion (5), which when in contact with the one or more additional layers (12), stops the threaded portion (2) from penetrading further into the one or more additional layers.

19. The rod connector of claim 18, wherein the stopper portion (10) comprise a flange (10) circumferentially encircling the longitudinal axis (4) of the rod connector and optionally have a disc or circular shape.

20. The rod connector of claim 19, wherein the flange has diameter (F) of from 10 mm to 50 mm, optionally between 25 mm to 45 mm, optionally between 34 mm to 36 mm.

21. The rod connector of claims 19 to 20, wherein the flange has thickness of at least 2 mm.

22. The rod connector of claims 19 to 21, wherein the flange is positioned at least 10 mm from promixal most protrusion of the head portion.

23. The rod connector of claims 19 to 22, wherein the flange is positioned at least 90 mm from the promixal most part of the cutting thread (3).

24. The rod connector of claims 19 to 23, wherein the flange further comprises one or more cutouts (11a) matching to a tool, optionally a wrench, configured for turning and tightening the rod connector into the additional layers.

25. The rod connector of claims 24, wherein the cutouts are linear and parallel and positioned oppositely at the edge/dcircumference of the flange and the flange between at the cutouts has a width/diameter (B) of between 10 mm to 40 mm, such as between 25 mm to 35 mm, such as between 31 mm to 33 mm.

26. The rod connector of any preceding claim, having total length (A) of between 200 mm to 500 mm,

- 19 - such as between 380 mm to 390 mm, such as between 385 mm to 386 mm.

27. The rod connector of any preceding claim, wherein the unthreded shaft portion has a cylinder or near-cylinder shape having a diameter of between 8 mm to 20 mm.

28. The rod connector of any preceding claim, wherein the rod connector is made of a synthetic polymer optionally reinforced by inorganic fibres.

29. The rod connector of claim 28, wherein the synthetic polymer is selected from polyamide (nylon) 66, Polyamide (nylon) 6, polypropylene or polyethylene or a combination thereof and wherein the inorganic fibres are selected from glass fibres or any composites thereof.

30. The rod connector of any preceding claim wherein the total lentgh (A) of the rod connector is between 385 mm to 386 mm; wherein the diameter (C) of the un-threaded shaft portion is between 9 mm to 11 mm; wherein the head portion have four cylinder formed protrusions pairwise oppositely positioned and aligned so that the first protrusion of the first pair is positioned in parallel to the first protrusion of the second pair in the longitudinal axis direction of the rod connector, wherein the diameter (D) of the protrusions are between 7 mm to 8 mm, and wherein the diameter of the head portion including the protrusions (G) is between 34 mm to 36 mm; wherein the rod connector comprises a circular shaped flange stopper portion having a diameter (F) between 34 mm to 36 mm, said flange comprising two parallel linear cutouts so having a diameter (B) between the cutouts between 31 mm to 33 mm; wherein the threaded portion has (i) a length (H) between 129 mm to 130 mm, (ii) a diameter (E) between 24 mm to 26 mm, (iii) a theading pitch (K) between 26 mm to 27 mm, and (iv) a threading depth (J) between 7 mm to 8 mm.

31. The rod connector of any preceding claim, wherein the where the connector head (7) further comprises an inner polygonal connector opening in the longitudinal axis of the rod connector designed as a female socket for receiving a male polygonal (hexagonal) drill bit fitted to engage into the polygonal female socket.

32. A rod connector (1) for connecting and binding together one or more additional layers (12) of materials, comprising an un-threaded shaft portion (la); a threaded portion (2) comprising a cutting thread (3) for screwing the rod connector (1) into the one

- 20 - or more additional layers (12) of materials in a longitudinal axis direction (4) of the rod connector (1) and optionally binding the one or more additional layers (12) of materials together; and a head portion (5) arranged opposite the threaded portion, configured to function as a female connector head (7) for adaptation into into a tool (18) so that the rod connector (1) can be screwed into the one or more additional layers (12) of materials.

33. The rod connector of claim 32 wherein a. the un-threaded shaft portion (la) is characterised according to claim 2; b. the cutting thread (3) is characterised according to claim 3 to 8; c. the rod connector comprises a stopper portion characterised according to claim 18 to 25; d. the rod connector is further characterised by the features of claims 26 to 29 and 31.

34. A connector system (14) comprising the rod connector (1) of claim 1 to 31 connecting a layer of a cast or molded layer (15) of material to one or more additional layers (12) of materials.

35. The system of claim 34, wherein the cast layer (15) is a concrete layer comprising mineral particles and cement, and/or reinforcement, and optionally has a layer thickness of at least 50 mm.

36. The system of claims 34 to 35, wherein the one or more additional layers (12) of materials comprises a thermally, electrically and/or hydrodynamically insulating material, optionally comprising a synthetic foam, such as a polystyrene foam or a mineral wool, such as rock or glass wool.

37. The system of claim 34 to 36, comprising two or more additional layers (12), bound together by the connector rod.

38. The system of claim 34 to 37 wherein the additional layers are in contact with each other, and at least one of the layers is in contact with the cast or molded layer.

39. The system of claim 34 to 38, wherein the one or more additional layers (12) have a thickness of at least 400 mm and wherein optionally the cutting tread (3) of the rod connector (1) penetrates through the one or more additional layers (12), optionally by at least 10 mm.

40. The system of claim 34 to 39 comprising two additional layers having a thichness each of 200 mm.

- 21 -

41. The system of claims 34 to 40, wherein the cast layer (15) is a concrete ground deck of a building, and the one or more additional layers (12) are insulation plates below the ground deck.

42. The system of claims 34 to 41, wherein a membrane is arranged between the cast layer and the one or more additional layers.

43. A tool (18) for mounting the rod connector (1) of claim 1 to 31 into one or more additional layers (12), comprising, in a connecting end (19), a female tool socket (20) configured to receiving the male connector head (7) in a male-female configuration.

44. The tool of claim 43, comprising at least one slit (21) in a longitudinal tool axis (22) of the tool, receiving the at least one protrusion (6) of the rod connector and allowing the female tool socket (20) to receive the male connector head.

45. The tool of claims 43 to 44, comprising at two oppositely positioned slits (21) receiving two oppositely positioned protrusions (6) of the male connector head.

46. The tool of claims 43 to 45, wherein the slit(s) further comprises bend(s) (23) substantially perpendicular or near-perpendicular to the longitudinal tool axis (22) of the tool, allowing the tool socket to lock into the male connector head (7) by sliding the at least one protrusion (6) into the bend (23) and twisting the tool.

47. The tool of claim 43 to 46, further comprising, in a tool end (24) arranged opposite the connecting end, a polygonal head (25) for insertion into a screwing device, optionally a drill bit on an electric screwdriver.

48. The tool of claims 43 to 47, wherein the polygonal head is a hexagonal head.

49. The tool of claims 43 to 48, wherein the polygonal head has a length of at least 40 mm and a longest diameter or diameter of at least 10 mm.

50. The tool of claims 43 to 49, wherein the tool has a total length, sufficuient for a worker standing upright on the one or more additional layers of materials (300) to mount the rod connector connected to the tool into the one or more additional layers of materials in an ergonomic working position.

- 22 -

51. The tool of claims 43 to 50, the total length of the tool is at least 400 mm.

52. An assembly (30) comprising the rod connector (1) of claims 1 to 31 connected with the tool (18) of claims 43 to 51.

53. A method for binding a cast or molded layer (15) of material to one or more additional layers (12) of materials thereby producing a system of claims 34 to 42, comprising screwing the rod connector (1) of claims 1 to 31 into the one or more additional layers (12) of materials, optionally using the tool (18) of claims 43 to 51, so that the head portion (5) extends from the one or more additional layers (12) of materials, and then casting the layer (15) of material so that it embeds the one or more protrusions (6) of the head portion (5), and allowing the cast layer (15) of material to solidify around the one or more protrusions (6) of the head portion whereby the cast layer (15) becomes bound to the one or more additiona layers (12) of material.

54. A method of producing the rod connector (1) of claims 1 to 31 or the tool (18) of claims 43 to 51, comprising providing a synthetic polymer optionally reinforced by inorganic fibres and injecting the synthetic polymer into a mould having the form of the rod connector or screwing tool and releasing the rod connector or screwing tool from the mould.

55. A building (100) or facility comprising a connector system (14) of claims 34 to 42.

* * *

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