FIELD OF THE INVENTION
The present invention is generally directed to anchor rod assemblies for use in concrete construction and particularly to anchor rod assemblies including a coupler sealed against concrete intrusion when embedded in concrete.
SUMMARY OF THE INVENTION
The present invention provides a plug for sealing one end of a threaded coupler from wet concrete, comprising a body including a flange portion for sealing around an outer edge of an opening of a coupler; and the body including a plug portion with radial projections for engagement inside a threaded coupler, the radial projections are configured to flex when the plug portion is pushed into or pulled out of the threaded coupler, the plug portion extending downwardly from the flange portion.
The present invention also provides a cap for sealing one end of a threaded coupler to be embedded in concrete, comprising a flexible body including a top wall for covering one end of a coupler; and a side wall extending downwardly from the top wall, the side wall for sealing engagement of the coupler.
The present invention also provides an anchor rod assembly for being embedded in a concrete, comprising a coupler having a first threaded end opening and a second threaded end opening, the coupler including a top edge, the first threaded end opening for being accessible with respect to a concrete surface of a concrete structure after concrete is poured; a seal for sealing the first threaded end opening from wet concrete, the seal having a top surface disposed above the top edge of the coupler, the top surface for being on a same level as the concrete surface to position the top edge below the concrete surface, the seal being configured to flex and rebound when hit; and an anchor rod including a first end portion threaded to the second threaded end opening.
The present invention provides an anchor rod assembly for being embedded in a concrete, comprising a coupler having a first threaded end opening and a second threaded end opening, the first threaded end opening for being accessible with respect to a concrete surface of a concrete structure after concrete is poured, the coupler having a top edge; a seal for sealing the first threaded end opening from wet concrete, the seal having a top surface disposed at a same level as the top edge of the coupler, the top surface for being on a same level as the concrete surface, the seal being configured to flex and rebound when hit; and an anchor rod including first end portion threaded to the second threaded end opening.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, partly in cross-section, of an anchor rod assembly embodying the present invention.
FIG. 2 is a perspective view of a threaded coupler used in the anchor rod assembly.
FIG. 3 is a cross-sectional view of the threaded coupler of FIG. 2.
FIG. 4 is side elevational view of a plug embodying the present invention for use with threaded coupler.
FIG. 5 is a perspective view of the plug of FIG. 4.
FIG. 6 is a cross-sectional view of the threaded coupler of FIG. 2 shown attached to a threaded rod in a first threaded position.
FIG. 7 is a cross-sectional view of the threaded coupler of FIG. 2 shown attached to a threaded rod in a second threaded position.
FIG. 8 is a cross-sectional view of the plug of FIG. 4 installed in the threaded coupler.
FIG. 9 is a cross-sectional view of FIG. 8 rotated 90° about the vertical axis, showing the flat surfaces on the vertical member and the plug flange portion deformed or flexed to provide greater seal with the coupler.
FIGS. 10A-10C are cross-sectional views of the plug inserted in the threaded coupler, showing several degrees of bending or flexing of the vertical member of the plug during construction of the concrete structure in which the coupler and the plug are used.
FIG. 11 is a cross-sectional view of the threaded coupler with the plug and the threaded rod attached, showing the use of the plug as a stop for the threaded rod to insure proper threaded engagement of the rod inside the coupler.
FIG. 12 is a cross-sectional view of the threaded coupler with the plug and the threaded rod attached, showing a dimple on the side of the coupler to lock the threaded rod to the coupler.
FIG. 13 is a side elevational view of FIG. 1, showing the anchor rod assembly embedded in concrete.
FIG. 14 is a perspective view of FIG. 13, showing the plug removed from the coupler after the concrete has cured.
FIGS. 15A-15C show the various possible positions of the vertical member of the plug during concrete finishing.
FIGS. 16A-33 are perspective cross-sectional views of other embodiments of the plug shown in FIG. 4 for use in a coupler.
FIGS. 34-37 are perspective cross-sectional views of a cap for sealing a coupler.
FIGS. 38A-38B are perspective cross-sectional views of the plug shown in FIG. 37 in actual use.
FIGS. 39-44C are perspective and cross-sectional view of the coupler used in the present invention.
FIGS. 45A-46C are perspective and cross-sectional views of a plug without a flange portion.
FIGS. 47A-48J are perspective and cross-sectional views of a plug with a flange portion.
FIGS. 49A-49F are perspective and cross-sectional views of a plug with a vertical member.
FIGS. 50A-50G are perspective and cross-sectional views of a plug with a flange portion and a vertical member.
FIGS. 51A-51D are perspective and cross-sectional views of a plug with a flange portion and multiple vertical members.
FIGS. 52A-52F are perspective and cross-sectional views of a plug with a convex top surface without a flange portion.
FIGS. 53A-56D are perspective and cross-sectional views of a plug with a flange portion with a convex top surface.
FIGS. 57A-58C are perspective and cross-sectional views of a cap.
FIGS. 59A-60F are perspective and cross-sectional views of a threaded plug portion.
FIGS. 61A-62C are perspective and cross-sectional views of a plug with plug portion with circular flat members.
FIGS. 63A-63F are perspective and cross-sectional views of a plug with plug portion made of crisscrossing members.
FIGS. 64A-64B are perspective and cross-sectional views of a plug with a hollow barrel-shaped plug portion, a hollow flange portion with a convex top surface and a hollow vertical member.
FIGS. 65A-65D are perspective and cross-sectional views of a plug with a tapered plug portion, recessed top portion and a vertical member flexibly bendable in the recessed top portion.
FIGS. 66A-66D are perspective and cross-sectional views of a plug with a tapered or conical plug portion.
FIGS. 67A-67C are perspective and cross-sectional views of a plug with helical ribs on the plug portion.
FIGS. 68A-68B are perspective and cross-sectional views of a plug with a plug portion with helical ribs and circular flat members.
FIGS. 69A-69D are cross-sectional views of a plug being pulled out of a coupler.
FIGS. 70A-70B are perspective views of a coupler with a plug and a rod with deformed thread.
FIGS. 71A-71I are perspective views of a plug with an arched top wall.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1, an anchor assembly 2 embodying the present invention is disclosed. The anchor assembly includes a rod holder 4 operably attached to a concrete formboard 6 by nails or screws 5.
The rod holder 4 is well-known in the art, such as disclosed in U.S. Pat. Nos. 8,943,777, 9,222,251, 10,577,816, incorporated herein by reference. The rod holder 4 may include a threaded opening which engages the bottom end of an anchor rod 8 to securely hold the rod vertically. The bottom end of the rod 8 is typically disposed a distance above the formboard 6 to advantageously seal the rod 8 for corrosion protection. The holder 4 may also provide vertical adjustment to the anchor rod 8, as disclosed in co-pending application Ser. No. 18/196,477, incorporated herein by reference.
The anchor body 10 is also well-known in the art. For example, a standard hex nut is shown as an anchor body. Other anchor bodies are disclosed in U.S. Pat. No. 9,097,001, incorporated herein by reference. The anchor body 10 provides the anchoring function when embedded in concrete. A threaded coupler 12 is threaded to the upper end of the rod 8. The anchor body 10 also securely locks the rod 8 to the rod holder 4 after the rod 8 is adjusted to achieve the correct vertical height of the coupler 12 prior to concrete pour. A seal in the form of a plug 14 advantageously seals one end of the coupler during concrete pour when the assembly 2 is embedded in concrete.
Referring to FIG. 2, the threaded coupler 12 is shown as being cylindrical, although the coupler 12 can have other shapes, such as hexagonal. The coupler 12 includes a threaded opening 16 and sight hole 18.
Referring to FIG. 3, showing the coupler 12 in cross-section, the threaded opening 16 includes a lower section 20 and an upper section 24. The lower section 20 may be provided with standard thread 22. The upper section 24 may be provided with oversized thread 26 to fit a coated threaded rod, such as a tie rod (not shown). The upper section 24 may also have the same standard thread 22. The sight hole 18 preferably provides a demarcation between the lower section 20 and the upper section 24 and an indicator of sufficient thread engagement of the rod 8 with the coupler 12, as will be discussed below. The thread 26 of the upper section 24 has a minor diameter 25 and a major diameter 27.
The sight hole 18 of the coupler 12 may be off center from the half-way point the coupler 12, providing a longer portion above the sight hole 18 than the lower portion below. The off center position of the sight hole advantageously allows the rod 8 to go past the sight hole 18 where the thread of the rod may be deformed through the sight hole to lock the rod in place.
Referring to FIGS. 4 and 5, the seal in the form of the plug 14 is provided to seal the upper portion 24 of the opening 16 against concrete intrusion. The plug 14 has a flange portion 28, a plug portion 30 below the flange portion 28, and a vertical member 32 disposed above the flange portion 28. The flange portion 28 is generally circular with a top surface 29. The plug portion 30 includes a cylindrical body 34 with radial projections in the form a thread 36 extending from the surface 38. The vertical member 32 projects vertically from the flange portion 28. The vertical member 32 includes a knob portion 40, which has a larger radial dimension than the rest of the vertical member 32, to advantageously provide a user a secure finger grip on the vertical member 32. The plug portion 30 may be provided with a flat circular member 293 (see FIG. 62A) to advantageously provide additional sealing by flexing and bending against the starting flank of the thread of the coupler 12 or chamfer at the opening 16 of the coupler 12.
The plug 14 and all the other embodiments of the plug disclosed herein are preferably made of plastic material that is elastic, flexible and/or squeezable, such as TPU or TPE material plastic material available from Americhem, Desmopan by Covestro, Ninjatek (Fenner Precision Polymers) or Sain Smart. The material is configured to flex and rebound when hit by a force, such as from the blades of a concrete finishing equipment. Other similar materials, such silicone or rubber material, may also be used.
Thermoplastic polyurethane (TPU) is a type of plastic that combines the characteristics of both rubber and plastic, offering properties such as elasticity, transparency, resistance to oil, grease, abrasion, and can be processed through methods like injection molding, extrusion, blow molding.
Thermoplastic elastomers (TPE) are a class of copolymers or a physical mix of polymers that combine the properties of thermoplastics and elastomers. They exhibit both thermoplastic and elastomeric properties, allowing them to be shaped into fabricated articles when heated and to return to their original shape after cooling. TPEs exhibit a wide range of physical properties, such as flexibility and elasticity similar to rubber, and strong tear and abrasion resistance.
The thread 36 is advantageously flat. The thread 36 is thin and long in the radial direction so it flexes and rebounds when the user pulls out the plug without an unscrewing motion. The upper thread portion 41 is advantageously thicker and shorter in the radial direction than the rest of the thread 36 to allow the user to further tighten the plug 14 in the opening 16. The upper portion 35 of the cylindrical body 34 is larger in diameter to make the upper thread portion 41 shorter in the radial direction and less flexible than the rest of the thread 36. The thread 36 has a minor diameter 43 and a major diameter 45.
Referring to FIG. 6, showing the coupler 12 and the rod 8 in cross-section, the top end 42 of the rod 8 is shown at the same level with the top part 44 of the sight hole 18. This position is the minimum engagement of the rod 8 in the coupler 12.
Referring to FIG. 7, showing the coupler 12 and the rod 8 in cross-section, the top end 42 of the rod 8 is past the top part of the sight hole 18 by more than one thread pitch. This is the maximum engagement of the rod 8 in the coupler 12. The minimum or maximum engagement of the rod 8 with the coupler 12 advantageously ensures that the connection will meet or surpass the intended load. The number of thread pitches (number of revolutions) between the minimum and maximum positions advantageously provides for height adjustment of the coupler 12.
Other reference points for designating minimum and maximum engagement of the rod with the coupler may be used. For example, the bottom part of the sight hole 18 may be designated as the minimum point, and the top part 44 of the sight hole the maximum point.
Referring to FIGS. 8 and 9, showing the coupler 12 and the plug 14 in cross-section, the plug 14 is shown attached to the coupler 12. The plug 14 may be installed by screwing the plug portion 30 into the opening 16. The plug 14 may also be simply pushed down into the opening 16 since the thread 36 will simply flex or bend into and out of thread of the coupler 12. The minor diameter 43 of the thread 36 is less than the minor diameter 25 of the thread 26 so that the thread 36 is only partly within the thread 26 to advantageously allow the thread 36 to flex or bend when the plug 14 is pushed down or pulled out from the coupler 12. The minor diameter of the thread 41 at the upper portion 35 is larger to advantageously make the thread 41 less flexible to allow the flange portion 28 to flex when the plug is screwed in further into the coupler for a tighter seal.
Referring to FIG. 9, the plug 14 is forced further into the opening 16 by screwing, allowing the flange portion 28 to flex, as generally shown at 37, and press against the top edge 39 of the coupler to provide greater seal to the opening 16. The flange portion 28, being thinner toward the center than at the outer periphery, creating space 33 over the top edge 39, advantageously facilitates the flexing 37 of the flange portion 28. The thicker and shorter thread portion 41 advantageously provides greater holding power when engaging the thread of the coupler to the plug to allow the flange portion 28 to flex and deform when the plug is screwed into the opening 16 after being pushed in. The vertical member 32 and the plug portion 30 are preferably axially aligned so that a vertical pulling force when applied to the vertical member 32 is evenly distributed to the plug portion 30 for ease of removal after use. The vertical member 32 includes flat surfaces 31 for providing additional gripping surfaces for a user when pulling the plug out of the coupler.
Referring to FIGS. 10A-10C, showing the coupler 12 and the plug 14 in cross-section. The vertical member 32 is elastic and able to flex and rebound when hit. The vertical member 32 is advantageously elastic and may flex slightly, as shown in FIG. 10A, or horizontally parallel to the horizontal line 50, as shown in FIG. 10B, or past the horizontal line, as shown in FIG. 10C. The flange portion 28 flexes and deforms, as generally shown at 52, to accommodate the bending or flexing of the vertical member 32. After bending, the vertical member 32 returns to its prior vertical position due to its elasticity, as shown in FIGS. 8 and 9. The material of the plug 14, being elastic advantageously resists material fatigue and breakage due to repeated flexing and bending, thus providing for a durable product.
Referring to FIG. 11, showing the coupler 12, the plug 14 and the rod 8 in cross-section, the rod 8 is threaded to the coupler 12 at its maximum engagement position of over one thread pitch past the sight hole 18. The bottom end of the plug portion 30 advantageously provides a stop for the rod 8 to ensure that the minimum thread engagement of the rod with the coupler 12 is attained. At the same time, the depth of penetration of the plug portion 30 into the coupler 12 as measured by the length of the plug portion 30, from the top of the coupler 12 to the bottom end 42, advantageously provides the minimum thread engagement for a strong connection for the rod 144 (see FIG. 38A) when the plug 14 is removed. The bottom end of the plug portion is advantageously disposed a distance above the top part 44 of the sight hole 18 at the maximum position of the rod 8 to allow for vertical adjustment of the rod 8, if needed. The flange portion 28 is shown flexed by screwing the plug 14 into the opening 16 after being pushed in.
Referring to FIG. 12, showing the coupler 12, the plug 14 and the rod 8 in cross-section, the engagement of the top end 42 of the rod 8 with the bottom end of the plug portion 30 assures that the rod 8 meets its minimum thread engagement for a strong connection. In addition, the extent of the bottom end of the plug portion 30 inside the coupler 12 assures the minimum thread engagement of the rod 144 when attached to the coupler after the plug 14 is removed. The the side of the coupler 12 may deformed with a dimple 19 to lock the rod 8 to the coupler 12 at the minimum thread engagement position. The dimple 19 may be provided by a tool, such as a punch and hammer, to depress the wall of the coupler into the thread of the rod 8, thus forcing and deforming the thread of the coupler into the thread of the rod. Locking the rod 8 and the coupler 12 advantageously avoids inadvertent vertical misalignment of the coupler during concrete construction.
The flange portion 28 is shown flexed or bent toward the opening 16 in FIGS. 11 and 12 by screwing the plug 14 into the opening 16 after being pushed in. The thicker thread portion 41 advantageously provides additional holding power.
Referring to FIG. 13, the anchor rod assembly 2 is shown embedded in a concrete structure 46, such as a concrete foundation, concrete beam, concrete slab, concrete deck, etc. The top surface 29 of the flange portion 28 is preferably disposed at the same level as the exterior top surface 48 of the concrete structure so that the top edge 39 of the coupler 12 is situated below the top surface 48 of the concrete structure when the plug 14 is removed after the concrete is cured. The vertical member 32 advantageously provides the means for indicating to the user the location of the coupler now embedded in concrete.
Referring to FIG. 14, after the concrete has cured, the plug 14 is removed, revealing the threaded opening 16 of the coupler 12. The threaded opening 16 is thus accessible with respect to the exterior top surface 48 of the concrete structure 46 after concrete is poured. The opening 16 may be used to connect to a threaded rod (not shown) for transferring a load to the concrete structure 46, such as a tie rod reinforcing a building wall. The top edge 39 of the coupler 12 is shown below the top surface 48 of the concrete (see also FIG. 13), advantageously providing the top surface 48 with a flat surface without protrusions to facilitate laying down other structures, such as a bottom plate of a stud wall, on the concrete surface 48.
Referring to FIGS. 15A-15C, the vertical member 32 may flex during concrete finishing of the surface 48. During concrete construction, such as pouring a slab, a power trowel is generally used to smooth the surface of the wet concrete slab. The power trowel includes several rotating blades. See, for example, https://en.wikipedia.org/wiki/Power_trowel. The vertical member 32 advantageously flexes and bends horizontally, as shown in FIG. 15C, when hit by the rotating blades, to increase its chances of not being severed. The elasticity of the vertical member 32 also prevents damage to the blades of the finishing equipment and interference with the operation of the power trowel. The vertical member 32 shown in FIG. 15B is shown rebounding to the vertical position shown in FIG. 15A after flexing horizontally as shown in FIG. 15C. The elasticity of the plug 14 advantageously provides resistance against being pulled out from a sideways force when hit by the trowel machine.
Referring to FIGS. 16A and 16B, the plug 14 may be modified as plug 54. FIG. 16B is a cross-sectional view of FIG. 16A. The vertical member 32 shown in the previous figures is replaced with three vertical members 56 extending upwardly and transversely from the flange portion 28. The vertical members 56 are preferably smaller in diameter than the vertical member 32. The plug portion 30 of the plug 14 may be modified as plug portion 60 in the form of a cylindrical member without a thread. The plug portion 60 is preferably friction fitted in the opening 16 to seal the opening. As with the vertical member 32, the vertical members provide the means for indicating the location of the coupler 12 after being embedded in concrete.
The vertical member 32 and the vertical member 56 are interchangeable in the various embodiments of the plug disclosed herein.
Referring to FIG. 17, a cross-section view of another embodiment of a plug for sealing the coupler 12 is shown. A single vertical member 56 is provided for the plug shown in FIG. 16A. The flange portion 28 has been removed. The single vertical member 56 is preferably co-axial of the plug portion 60. The top surface 61 of the plug portion 60 is preferably disposed at the same level as the top edge 39 of the coupler 12.
Referring to FIG. 18, a cross-sectional view of another embodiment of a plug is shown. The plug shown in FIGS. 16A-16B has been modified with the removal of the vertical members 56.
Referring to FIG. 19, another embodiment of a plug for sealing the coupler 12 is shown in cross-section. The flange portion 28 shown with the plug in FIG. 16A has been modified into a flared portion 62 which is recessed into the opening 16. The flared portion 62 has ramp surface 64 just below the top surface 61 that corresponds to the thread angle or chamfer in the opening just below the top edge 39 to seal the opening 16.
Referring to FIG. 20, another embodiment of a plug in the coupler 12 is shown in cross-section. The top surface of the plug shown in FIG. 17 is provided with a raised top portion 65 disposed above a flat circumferential top edge surface 63. When plug is used in the coupler 12, the edge surface 63 is positioned at the same level as the top edge 39 of the coupler 12. The vertical member 56 has been removed.
Referring to FIG. 21, another embodiment of a plug for sealing the coupler 12 is shown cross-section. The plug 14 is modified as a tapered or conical plug 66 force fitted into the opening 16 to seal the opening from the wet concrete during construction of a concrete structure, such as a foundation, concrete slab, concrete deck, concrete beam, etc. The upper portion 63 of the plug 66 advantageously seals the opening of the coupler 12.
Referring to FIG. 22, another embodiment of a plug for sealing the coupler 12 is shown in cross-section. The plug shown in FIG. 18, the flange portion 28 is provided with a raised portion 68, preferably convex-shaped. The raised portion 68 advantageously allows the blades of the concrete finishing equipment to ride over the top. The compressible material of the plug advantageously allows the blades of the equipment to squeeze down the raised portion 68 without interfering with the finishing of the concrete surface. The plug portion 30 is tapered or conical with a wider portion 70 that is force fitted into the upper thread of the coupler 12 to advantageously hold the flange portion 28 in sealing contact with the upper edge 39 of the coupler 12.
Referring to FIG. 23A, another embodiment of a plug for sealing the coupler 12 is shown in cross-section. The rod 8 is shown attached to the coupler 12. The plug 14 has been modified as a plug 72, which includes a tapered or conical plug portion 74, cap portion 76 and a vertical member 78. The cap portion 76 has a top recess 80 into which the vertical member 78 flexes when hit by the blades of a power trowel during concrete finishing. The cap portion 76 includes side surface 82 that corresponds to the thread angle of the coupler 12 for a proper seal. The plug portion 74 includes a wider upper portion 84 that is force fitted into the upper portion of the opening 16 of the coupler 12 to further seal the opening 16. The bottom end of the plug 72 serves as an indicator for the proper penetration of the rod 8 into the coupler 12 when the top end of the rod 8 engages the bottom of the plug 72.
Referring to FIG. 23B, the assembly of FIG. 23A is shown embedded in concrete. The vertical member 78 normally extends vertically upward above the concrete top surface 48. The vertical member 78 flexes and bends into the recess. The top edge 39 of the coupler 12 is flush with the top surface 48 of the concrete. The vertical member 78 advantageously provides the means for indicating the location of the embedded coupler 12 in the concrete structure 46.
Referring to FIG. 24, another embodiment of a plug in the coupler 12 is shown in cross-section. The plug shown in FIGS. 16A-16B is modified where a single vertical member 56 is provided. The plug portion 30 is hollow with the provision of a blind hole 86. The plug portion 30 is provided with circumferential fins 88 where portions 90 are received within the thread flanks and other portions 92 are bent or flexed against the thread crests. The fins 88 are preferably spaced from each other corresponding to the thread pitch of the coupler.
Referring to FIG. 25, another embodiment of a plug in the coupler 12 is shown. The rod 8 is also shown in cross-section. The plug shown in FIG. 24 is modified where the plug portion 30 is tapered and hollow and the fins 88 are not used. The plug portion 30 includes a lower portion 94 that is force fit in the intermediate section of the opening 16. The opening 16 has three threaded sections with three diameter sizes to advantageously accommodate three correspondingly sized rods. The hole section 96 has the largest diameter, hole section 98 a smaller diameter and the hole section 100 the smallest diameter. The bottom end of the plug portion 30, disposed at the juncture of the middle hole section 98 and the bottom hole section 100, provides a stop for the rod 8 to keep the end of the rod 8 from encroaching into the middle hole section 98 and thereby reduce the thread engagement available for use by another rod. The bottom end of the plug portion 30 provides a stop to the end of the rod 8 to indicate the required amount of thread engagement of the rod with the coupler 12.
Referring to FIG. 26, another embodiment of a plug in the coupler 12 is shown in cross-section. The plug shown in FIG. 24 is modified where the fins 88 are not used and the plug portion 30 is hollow and shorter. The plug portion 30 is force fitted into the opening 16. The coupler 12 has 3 different diameter openings as shown in FIG. 25.
Referring to FIG. 27A, another embodiment of a plug in the coupler 12 is shown in cross-section. The plug 14 is modified as plug 102, which includes a tubular, cylindrical plug portion 60 with a sidewall 109 and a cap portion 106. The cap portion 106 has a top recess 108 with a convex shape with the dome top 110 preferably level with the top edge 39 of the coupler 12. The cap portion 106 includes a sidewall 107 with a ramp surface 64 that correspond to the thread angle of the coupler 12 or chamfer at the opening 16 for a proper seal. The cap portion 106 includes a top edge 111, which is preferably lined up at the same level as the top edge 39 of the coupler 12. The bottom edge of the plug portion 104 advantageously lines up with the top side 44 of the sight hole 18 to provide a stop for the rod 8.
Referring to FIG. 27B, the coupler 12 with the plug 102 is shown embedded in concrete 46 with the top surface 48 of the concrete structure at the same level as the top edge 39 of the coupler 12 and the dome top 110 of the plug.
Referring to FIG. 28, an embodiment of a plug and an embodiment of the coupler 12 are shown in cross-section. The coupler 12 is modified with a cylindrical portion 114 at the top portion of the opening 16. The cylindrical portion 114 is provided with a circumferential groove 116. The plug shown in FIG. 26 may be modified with a circumferential rib 118 for being received within the groove 116. The flange portion 28 may be modified to be recessed into the opening 16. The top side of the flange portion 28 is flush with the top edge 39 of the coupler 12.
Referring to FIG. 29, an embodiment of a plug in the coupler 12 is shown in cross-section. The plug is similar to the plug shown in FIG. 18, except that the flange portion 28 is modified to have a convex-shaped top surface 120 and the plug portion 60 is modified to be tubular and barrel-shaped, being wider in the middle portion 122 and narrower at the top and bottom portions 124. The flange portion 28 presses against the top edge 39 of the coupler 12 to seal the opening 16. The middle portion 122 is forced fit into the opening 16 to hold the plug in place. The flange portion 28 is advantageously compressible downwardly when hit by the rotating blades of a power trowel.
Referring to FIG. 30, the assembly of FIG. 29 with the rod 8 are shown embedded in the concrete structure 46. The convex top surface 120 is shown above the concrete top surface 48. The top 120 is easily visible on the concrete surface 48. The top 120 is advantageously flexible so that it compresses flat when hit by the blades of a power trowel when finishing the concrete surface.
Referring to FIG. 31, another embodiment of a plug in the coupler 12 is shown in cross-section. The plug is similar to the plug shown in FIG. 29, except that the convex top surface 120 is hollow underneath to provide for easier flexing toward the opening 16 when hit by the rotating trowel blades. The plug portion 60 is cylindrical to advantageously maximize contact with the coupler thread and tubular to advantageously provide additional flexing to facilitate insertion into the coupler.
Referring to FIG. 32, another embodiment of a plug in the coupler 12 is shown in cross-section. The plug is similar to the plug shown in FIG. 18, except that the plug portion is hollow, preferably tubular and cylindrical.
Referring to FIG. 33, another embodiment of a plug in a coupler is shown in cross-section. The plug is similar to the plug shown in FIG. 19, except that the vertical member 56 is not provided and the plug portion 60 is hollow. A tapered or conical blind hole 126 is preferably used to advantageously provide stiffness at the upper portion of the plug portion 60 to provide stronger contact with the coupler thread and additional flexibility at the lower portion when inserting the plug portion into the coupler opening.
Referring to FIG. 34, another embodiment of a plug in a coupler is shown in cross-section. A plug 130 is similar to the plug shown in FIG. 28, except that the vertical member 56 and the circumferential rib 118 are not provided. The plug 130 is disposed inside the cylindrical portion 114 of the opening 16. The plug 130 has a convex top wall 132 that projects above the concrete surface 48 when the coupler 12 is embedded in the concrete structure. The convex top wall 132 advantageously provides the means for indicating the location of the coupler 12.
Referring to FIG. 35, a seal in the form of a cap 134 fits over the opening 16 of the coupler 12. The cap 134, the coupler 12 and the rod 8 are shown in cross-section. The cap 134 includes a domed or convex top wall 136 and side wall 138 that corresponds to the exterior shape of the coupler 12, such as cylindrical or hexagonal. The cap 134 provides a secure attachment to the sides of the coupler 12. The cap 134 is shown on the coupler 12 embedded in concrete 46. The corner of the top of the wall 136 and the side wall 138 is preferably at the same level as the top surface 48 of the concrete structure 46. The domed top wall 132 advantageously protrudes above the top surface 48 of the concrete as a means for indicating the location of the embedded coupler 12 after the concrete has cured.
Referring to FIG. 36, the cap 134 is disposed over the coupler 12 shown in FIG. 34. The coupler 12 has the cylindrical surface 114 shown in FIG. 34.
Referring to FIG. 37, the cap 134 may be modified with radial grooves 139 disposed underneath the top wall 136. The grooves 138 reduce the thickness of the top wall 136, advantageously allowing the breakage of the top wall along the grooves 138 when a rod 144 (FIG. 38A) is inserted into the coupler 12. The upper end 140 of the opening 16 is larger in diameter than the rest of the opening to accommodate the broken portions 142 of the top wall 136 when the rod is inserted.
Referring to FIGS. 38A-38B, a rod 144 is attached to the coupler 12 by breaking through the top wall 136 of the cap 134. The broken portions 142 are pushed to the side into the larger diameter portion 140 of the opening 16. The coupler 12, the cap 134 and the rod 8 are shown embedded in the concrete structure 46.
Referring to FIG. 39, the coupler shown in FIG. 34 is shown without the plug 130. The opening defined by the cylindrical surface 114 has a larger diameter than the minor diameter of the threaded opening 16 to create a shoulder 113, which provides a stop for the sidewall or plug portion 30 (FIG. 26) of the plug 130.
Referring to FIG. 40, a circumferential groove 116 is provided in the cylindrical surface 114 for receiving a corresponding projection 118 on the plug portion 30, as shown in FIG. 28.
Referring to FIGS. 41A and 41B, the coupler 12 may be modified to delete the sight hole 18. The bottom of the plug when placed inside the coupler will provide a stop to the rod 8 to insure the correct number of thread engagement of the rod inside the coupler. The top end portion 154 is provided with an inverted cone surface 156 and a flange portion 158 just below the top edge 39. The inverted cone surface 154 is used to mate with a corresponding cone surface of a cap, as shown in FIG. 44C.
Referring to FIGS. 42A and 42B, the coupler 12 may be modified with an internal cone surface 160 and a flange portion 158 just below the top edge 39 to mate with a profile on a bottom surface of a cap, such as shown in FIG. 43C where the circumferential rib 168 is shaped to mate with the cone surface 160 and the flange portion 158.
Referring to FIGS. 43A-43B, the top edge surface 39 of the coupler 12 may be modified with a circumferential groove 164 with a partly circular cross-section. FIG. 43B is a cross-section of FIG. 43A.
Referring to FIG. 43C, an embodiment of a cap 166 placed over the opening of the couple 12 is shown in cross-section. The cap 166 with a circumferential projection 168 closes the top opening of the coupler 12 with a top wall 169. The projection 168 is disposed underneath the top wall 169 to lock into the groove 164. The vertical member 56 extends upwardly to locate the cap 166 in the concrete 46 (see FIG. 13). The projection 168 and the groove 164 are preferably partly circular in cross-section.
Referring to FIGS. 44A and 44B, the coupler 12 may be modified with an outside circumferential groove 167 just below the top edge 39 with a conical surface 170 and a shoulder 172. FIG. 44B is a cross-section of FIG. 44A.
Referring to FIG. 44C, the cap 166 has a sidewall 176 extending downwardly from the top wall 169. The sidewall 176 includes an inner circumferential projection 178 which mates with the groove 167. The vertical member 56 extends upwardly to locate the plug 166 in the concrete 46 (see FIG. 13). The groove 167 and the projection 178 are preferably circular in plan view, but other shapes, such as hexagonal, may also be used, depending on the exterior shape of the coupler 12. FIG. 44C is shown in cross-section.
Referring to FIG. 45A, the conical plug 66 of FIG. 21 may be modified as a cylindrical plug 166. The plug 166 may be made hollow with a blind hole 188, providing a top wall 184 and a longitudinal sidewall 186, as shown in FIG. 45C. Advantageously less material is used in making the plug 66. The blind hole 188 advantageously provides additional flexibility to the sidewall 186 during insertion into the coupler 12.
Referring to FIGS. 46A-46C, the plug 66 of FIG. 21 may be modified as a plug 190 with a cylindrical portion 193 and a tapered or conical plug portion 192 with conical outside surface. The plug 190 may be solid, as shown in FIG. 46B, or hollow, as shown in FIG. 46C, with a blind hole 188 to provide additional flexibility to the conical plug portion 192 during insertion into the coupler 12. The cylindrical portion 193 advantageously increases contact with the coupler thread for greater sealing function. The tapered or conical portion 192 advantageously facilitates the insertion of the plug into the coupler 12.
Referring to FIGS. 47A and 47B, the plug shown in cross-section in FIG. 33 is designated as plug 194 and is shown outside the coupler 12. The plug portion 60 is shown hollow with the tapered hole 126, but may be solid, as shown in FIG. 47C. The plug 194 has a top end portion 196 with the flared portion 62, which has the circumferential ramp surface 64, as shown in FIG. 47C. The ramp surface 64 corresponds to the thread angle or chamfer just below the top edge 39 of the coupler 12 to seal the opening 16, as shown in FIG. 19.
Referring to FIGS. 47D-47E, the plug portion 60 may be tapered or conical, solid or hollow with a blind hole 188, which may be cylindrical or tapered or conical.
Referring to FIG. 47F-47G, the plug shown in FIG. 18 is shown outside the coupler 12. The plug portion 60 is shown solid, but may be hollow with the blind hole 188, as shown in FIG. 47H (see also FIG. 32). The plug portion 60 may be tapered or conical, as shown in FIGS. 471 and 47J. The flat horizontal surface 204 is configured to contact the top edge 39 of the coupler 12, as shown in FIG. 18.
Referring to FIGS. 48A-48J, the plug shown in FIGS. 18 and 32 may be modified as a plug 206 with a top end portion 208 and an overhang portion 210 that replaces the flange portion 28. The overhang portion 210 has a recess 212 with an outer sidewall 214 and a top wall 216. The top edge 39 of the coupler 12 fits within the recess 212 and the sidewall 214 is positioned outside the coupler, as generally shown with the cap 134 in FIG. 35. The plug portion 60 of the plug 206 may be solid, as shown in FIGS. 48B, 48D, 48E, 48F, 48G, 48I and 48J, or hollow with a blind hole 188, as shown in FIGS. 48C and 48H. The plug portion 60 may be cylindrical, as shown in FIGS. 48A, 48B, 48C, 48F and 48G or tapered or conical, as shown in FIGS. 48D, 48E, 48I and 48J.
Referring to FIGS. 48F-48J, the sidewall 214 of the recess 212 has an internal hexagonal shape 218 in plan view to conform to a cross-sectional hexagonal shape of the coupler 12. Other shapes may be used to correspond to the exterior cross-sectional shape of the coupler.
Referring to FIGS. 49A-49C, the plug shown in FIG. 17 is shown outside the coupler 12 and designated as plug 220 with the vertical member 56, which extends upwardly from the top portion 224. The vertical member 56 preferably extends along a central axis of the plug 220. The plug portion 60 may be solid, as shown in FIG. 49B, or hollow with a blind hole 188, as shown in FIG. 49C.
Referring to FIGS. 49D and 49E, the plug 220 may be modified where the plug portion 60 is tapered or conical.
Referring to FIG. 49F, the plug 220 may be modified as plug 221 with a conical top surface 223 between the plug portion 60 and the vertical member 56. The conical surface 223 advantageously provides a transition to the vertical member 56 for the blades of a concrete finishing equipment. A circumferential shoulder or rib portion 225 is provided at the bottom portion of the plug portion 60. The shoulder portion 225 advantageously meshes with the coupler thread to help hold the plug in place. The plug portion 60 is advantageously friction fit in the coupler opening 16 to seal the coupler from the wet concrete during construction of the concrete structure 46.
Referring to FIGS. 50A-50D, the plug shown in FIG. 19 is shown outside the coupler 12. The plug portion 60 may be solid, as shown in FIGS. 50A and 50B, or hollow, as shown in FIGS. 50D, with the blind hole 188. The plug portion 60 may be cylindrical, as shown in FIGS. 50A and 50B, or tapered or conical, as shown in FIGS. 50C and 50D. The flared portion 62 includes the ramp surface 64.
Referring to FIGS. 50E-50G, the plug shown in FIG. 16B may be modified with a single vertical member 56. The plug portion 60 may be hollow with a blind hole 188.
Referring to FIGS. 51A-51D, the plug shown in FIGS. 16A and 16B is shown outside the coupler 12. The plug portion 60, shown solid in FIG. 16B, may be hollow with the blind hole 188, as shown in FIG. 51B. The multiple vertical members 56 advantageously provide additional grabbing surfaces when pulling the plug from the coupler 12 and provide additional visibility above the concrete surface to provide location information when it is time to pull the plug out. The multiple vertical members 56 further provides additional chances that one or more of the vertical members will survive from being hit by the blades of the concrete finishing machine during construction. Although the flange portion 28 is shown with the horizontal surface 204, it should be understood that the multiple finger embodiment is also applicable to the embodiment with the ramp surface 64 underneath the flared portion 62, as shown in FIG. 50B.
Referring to FIGS. 52A-52C, the plug 166 shown in FIG. 45A may be modified as plug 228 with a convex top surface 230. The plug 228 may be solid, as shown in FIG. 52B, or hollow or tubular, as shown in FIG. 52C. Placement of the plug 228 in the coupler 12 is the same as shown in FIG. 20. The corner edge 229 is preferably lined up to the same level as the top edge 39 of the coupler 12 when placed inside the opening 16, as generally shown in FIG. 20.
Referring to FIGS. 52D-52F, the plug shown in FIG. 20 is shown outside the coupler 12 and is designated as plug 229. The top surface 65 includes a circular horizontal lower edge 63. The plug 229 may be solid, as shown in FIG. 52E, or hollow or tubular, as shown in FIG. 52F.
Referring to FIGS. 53A-53B, the plug 194 shown in FIGS. 47A-47B may be modified as plug 234 with the flared portion 62 forming a circular edge at the bottom of the top surface 230. The flared portion 62 includes an underneath ramp surface 64 which is configured to mate with a corresponding surface on the top end portion of the coupler 12, as shown in FIG. 19. The plug portion 60 may be tubular with a top wall 240 forming the top wall surface 230. A rib portion 242 runs vertically on an inside surface of the side wall 244 and a bottom surface of the top wall 240.
Referring to FIGS. 54A and 54B, the plug 102 shown in FIG. 27A is shown outside the coupler 12. The cap portion 106 includes a sidewall portion 107 extending upwardly from the bottom portion of the dome top 110 to form a recess 108. The sidewall 107 includes a ramp surface 64 configured to mate with a corresponding surface on the top end portion of the coupler 12. The plug portion 104 includes a sidewall 109 joined to the dome top 110.
Referring to FIGS. 55A-55B, the plug shown in FIG. 31 is modified with a solid plug portion 60 and is designated as plug 250. The top convex surface 120 extends beyond the plug portion 60 to form a flange portion 28. The flange portion 28 includes an underneath horizontal surface 256 that engages the top edge 39 of the coupler 12 to seal the coupler.
Referring to FIGS. 55C-55E, the plug portion 60 may be hollow with a side wall 258 and a top wall 260 that forms the top convex surface 120.
Referring to FIGS. 55F, the side wall 258 may include a slot 262 to advantageously allow the side wall 258 to compress in diameter when the plug is being inserted into the coupler 12.
Referring to FIGS. 56A-56B, the plug 206 shown in FIGS. 48D-48E may be modified as plug 264 with a convex top surface 230. The plug portion 60 is preferably tubular and tapered or conical. The convex surface 230 is formed by a top wall 260 that flexes downwardly when hit by the blades of a concrete finishing power trowel equipment. The plug 264 is attached to the coupler 12 in a similar way as the cap 134 shown in FIG. 35, but with the addition of the plug portion 60.
Referring to FIGS. 56C-56D, the plug portion 60 may be solid and tapered or conical. The recess 212 has an internal hexagonal surface shape 218 in plan view to conform to an outside hexagonal cross-sectional shape of the coupler 12.
Referring to FIGS. 57A-57B, the cap 134 shown in FIG. 35 is depicted with more details. The recess 266 below the dome top 136 shows a hexagonal perimeter to mate with the hexagonal cross-sectional shape of the coupler 12.
Referring to FIGS. 58A-58C, the cap 134 shown in FIG. 37 is depicted with more details. The underside of the dome top 136 includes crisscrossing grooves 138 to advantageously weaken the dome top 136 when the rod 144 is forced against the dome top 136 to attach to the coupler 12. The dome top 136 breaks apart into broken portions 142 along the grooves 136, producing an opening 270 for the rod 144.
Referring to FIGS. 59A-59B, a plug 272 is similar to the plug shown in FIG. 50G, except for the addition of the radial projection in the form of thread 276 to the plug portion 60. The thread 276 corresponds to the thread of the coupler 12. The plug portion 60 is shown hollow with the provision of a blind hole 188 but may be solid as shown in FIG. 50F. Placement of the plug 272 in the coupler 12 is similar to that shown in FIG. 16B.
Referring to FIGS. 59C-59D, the thread 276 may be modified as thread 278, which has rounded crest portions 278 that stop short of the roots of the thread of the coupler 12. The rounded thread 278 is configured to seal the thread of the coupler by jamming against the adjacent flanks of the coupler thread.
Referring to FIGS. 60A-60B, the plug shown in FIG. 50G may be modified with the addition of a single revolution thread 280 disposed at a bottom portion of the plug portion 60.
Referring to FIGS. 60C-60D, the thread 280 may be disposed at an upper portion of the plug portion 60.
Referring to FIGS. 60E-60F, the thread 280 may be modified as a segmented thread 282 disposed at an upper portion of the plug portion 202. The segmented thread 282 may also be disposed at a lower portion of the plug portion 202 as shown in FIG. 60A.
In the embodiment shown in FIGS. 60A-60E, sealing of the coupler 12 is accomplished by the flange portion 28 and the plug portion 60, assisted by the thread 280 in pulling the flange portion 28 against the top edge 39 of the coupler 12.
Referring to FIGS. 61A-61B, the plug shown in FIG. 50G may be modified as plug 283 where the plug portion 60 is provided with radial projections in the form of a series of flat circular ring members 284, separated from adjacent ring members at a distance equal to the pitch of the thread of the coupler 12. The flat circular ring members 284 advantageously flex and bend when the plug 283 is inserted into the coupler 12 without a screwing motion.
Referring to FIGS. 61C-61D, the circular flat ring members 284 may be modified as a single flat circular ring member 288 disposed at a lower portion of the plug portion 60.
Referring to FIGS. 61E-61F, the single flat circular ring member 288 may be disposed at an upper portion of the plug portion 60. The flat circular member 288 advantageously provides additional sealing by flexing and bending against the starting flank of the thread of the coupler 12 or chamfer of the opening 16.
Referring to FIG. 62A, the plug 283 may be modified as plug 290 with a lower cylindrical portion 292, which corresponds to or slightly larger than the minor diameter of the thread of the coupler 12. The lower cylindrical portion advantageously provides a frictional fit with the minor diameter of the thread of the coupler 12 to help hold the plug 290 inside the coupler. The plug portion 60 has a cylindrical portion 294 from which the circular flat members 284 extend radially. The cylindrical portion 294 has a diameter smaller than the minor diameter of the thread of the coupler 12.
Referring to FIGS. 62B-62C, the circular flat members 284 flex and bend against the crest 296 of the thread of the coupler 12. The space 298 between the crest 296 and the cylindrical portion 294 provides clearance for the flexing and folding of the flat circular members 286 against the crest 296. The flexing and folding of the flat circular members 284 advantageously seal the thread of the coupler 12 against the wet concrete during pouring of the concrete. The top flat circular member 293 advantageously provides additional sealing by flexing and bending against the starting flank of the thread of the coupler 12 or the chamfer at the opening 16 of the coupler. The lower cylindrical portion 292 advantageously provides a frictional fit with the minor diameter surface of the thread of the coupler 12. The plug 290 is installed by pushing the plug portion 202 down into the opening 16 of coupler 12, causing the flat circular members 284 to flex and bend against the crest 296 of the thread of the coupler. The plug 290 may be removed by simply pulling up on the vertical member 56.
Referring to FIGS. 63A-63C, the plug shown in FIG. 50F may be modified as plug 300 where the plug portion 60 is modified as crisscrossed wall members 302. The outer edges 304 of the wall members 302 include radial projections in the form of a series of knobs 306 that are positioned on the respective outer edges 304 to follow the pitch and helix angle of the thread of the coupler 12. The knobs 306 are configured to be disposed between the flanks of the thread of the coupler 12 when the plug 300 is inserted into the opening 16 of the coupler 12. A cylindrical portion 308 at the upper end of the plug portion 202 and the horizontal undersurface 204 advantageously provide the sealing function of the plug 300. The cylindrical portion 308 may be hollow, as shown in FIG. 63C. Placement of the plug 300 in the coupler 12 is similar to that shown in FIG. 24.
Referring to FIG. 63D, the knobs 306 may be removed. The width of each of the members 302 may be slightly greater than the minor diameter of the thread of the coupler 12, to advantageously provide a friction fit inside the opening 16 of the coupler 12.
Referring to FIGS. 63E-63F, the plug 300 may be modified as plug 310. The members 302 are tapered and the vertical member 56 is not used. The convex top surface 230 is used to locate the position of the coupler 12 in the concrete structure. The cylindrical portion 308 may be hollow.
Referring to FIGS. 64A-64B, the plug shown in FIG. 29 may be modified as plug 312 with the addition of the vertical member 56. The vertical member 56 and the flange portion 28 may be hollow, as shown in FIG. 64B. The convex shaped top 120 may be hollow below the top wall 314.
Referring to FIGS. 65A-65D, the plug 72 shown in FIG. 23A is shown outside the coupler 12. The vertical member 78 flexes between an upright position, as shown in FIGS. 65A-65B and a bent position in FIGS. 65C-65D. The vertical member 78 advantageously bends into the recess 80 for protection when hit by the blades of the concrete finishing equipment. The vertical member 78 returns to the upright position when there is no force acting on it from the side. The vertical member 78 extends past the top of the cap portion 76 to be visible above the concrete surface 48 (see FIG. 23B). When installed in the coupler 12, the top edge surface 77 of the plug 72 is preferably disposed at the same level as the top edge 39 of the coupler.
Referring to FIGS. 66A-66B, the plug 206 shown in FIGS. 48D-48E may be modified as plug 318 with the addition of the vertical member 56. The plug 318 is used with the coupler 12 in a similar way as the cap 134 shown in FIG. 35 but with the addition of the plug portion 60 and the vertical member 56.
Referring to FIGS. 66C-66D, the plug shown in FIGS. 50E-50F may be modified as plug 320 with the plug portion 60 being tapered or conical and the outer edge of the overhang portion 198 being a beveled edge 322. The beveled edge 322 advantageously provides a ramp for the blades of a concrete finishing equipment to ride over. The plug 320 is used with the coupler 12 in a similar way as shown in FIG. 25.
Referring to FIG. 67A, the plug shown in FIG. 50E may be modified with the addition of radial projections in the form of circular ribs 324 around the cylindrical plug portion 60 for engaging the thread of the coupler 12. The circular ribs 324 engage the thread of the coupler 12 as shown in FIG. 62B.
Referring to FIG. 67B, a radial projection in the form of a single helical rib 326 is disposed at a mid-portion of the plug portion 60. The cylindrical portion of the plug portion 60 is friction fitted to the opening of the coupler 12. The helical rid 326 is configured to engage the thread of the coupler 12.
Referring to FIG. 67C, the helical rib 326 may be placed at the upper portion and lower portions of the plug portion 60. The vertical member 56 may include a conical portion 328 to advantageously facilitate the riding of the blades of the concrete finishing equipment over the vertical member 56.
Referring to FIGS. 68A-68B, the plug shown in FIG. 67C may be modified as plug 330 having radial projections in the form of multiple circular flat members 284 disposed between the upper and lower helical ribs 326. The helical ribs 326 secure the plug 330 in the opening of the coupler 12 and the circular flat members 294 flex and bend against the crests of the thread of the coupler to seal the coupler in a similar way as shown in FIG. 62C. The flange portion 28 is undercut underneath to create the space 33 to help flex the flange portion 28 against the top edge 39 of the coupler to better seal the coupler, as already discussed with the plug 14 above.
Referring to FIGS. 69A-69B, the plug 14 is shown in several stages of being pulled from the coupler 12 after the concrete structure 46 has cured. Referring to FIG. 69A, the flange portion 28 is shown deformed at 37 due to tightening of the upper thread 41 against the thread 16 of the coupler 12. Referring to FIGS. 69B and 69D, the flat thread 36 of the plug portion 30 is flexing and bending downwardly against the thread of the coupler 12 as the plug is being pulled out. FIG. 69C shows the plug 14 completely out of the coupler 12.
Referring to FIG. 70A, the thread 332 of the rod 8 is visible through the sight hole 18, indicating that the rod 8 has reached the minimum thread engagement with the coupler 12 for a strong connection. The rod 8 may be locked to the coupler 12 after the rod's reaching the minimum thread engagement with the coupler and the coupler's adjustment to the desired height above the formboard. Locking may be accomplished by deforming the sight hole 18 against the thread 332 or deforming the thread 332. Referring to FIG. 70B, the thread 332 is shown deformed at 334 by means of a punch inserted through the sight hole. The deformed thread 334 advantageously locks the rod at the proper position after engaging the bottom of the plug 14, as shown in FIG. 69A. The rod 8 may be adjusted to bring the coupler 12 at the desired height above the formboard 6 and then locked in place by deforming the thread 332 of the rod 8 visible through the sight hole 18. A nut threaded to the rod 8 and engaging the bottom of the coupler 12 may also be used to lock the rod to the coupler, as shown in U.S. Pat. No. 9,222,251, incorporated herein by reference. Also see FIG. 12 for ways of locking the rod 8 to the coupler 12, as already described above.
It should be understood that the plug portion of any of the plugs disclosed herein may be used as a stop for the rod 8 when inserted in the coupler 12 to indicate the required minimum thread engagement of the rod with the coupler for a strong connection. The penetration of the plug portion inside the coupler also provides space after the plug is removed for the minimum thread engagement of the rod 144 (FIG. 38A) to meet the design load of the connection.
Referring to FIG. 71A, the plug 14 shown in FIG. 4 may be modified as plug 334 where the flange portion 28 is provided with an arched bridge or arched top wall portion 336 without the vertical member 32. The arched wall portion 336 is configured to flex and flatten downwardly into the space 338 below the arched portion 336 towards the top surface 29 when the blades of the concrete finisher hit it. After the concrete is cured, the arched top wall portion 336 may be visible above the top surface of the concrete 46, similar to what is shown in FIG. 30. If the arched wall portion 336 is covered with a thin layer concrete during construction, the arched wall portion 336 may be easily uncovered with a few strikes by a tool, such as a hammer, since the arched wall portion 336 is flexible and will not support the thin layer of concrete when hit by the tool.
Referring to FIG. 71B, the vertical member 56 has been added to the top of the arched wall 336 to increase the visibility of the location of the coupler 12 when embedded in the concrete structure 46.
Referring to FIG. 71C, the single vertical member 56 is replaced with multiple vertical members 56 with smaller diameter. Having multiple vertical members 56 increase the chance that at least one of the vertical members will survive from being hit by the blades of the concrete finishing equipment.
Referring to FIG. 71D, the vertical member 56 attached to the arched wall 336 is modified with an enlarged portion 340 and a smaller diameter portion 342. The enlarged portion 340 advantageously provides a gripping shape for pulling the plug from the coupler after the concrete has dried. If the vertical member 56 is cut off by the blades of the concrete finishing equipment, a screwdriver may be inserted into the space 338 to pry the plug from the coupler after the concrete has dried. The plug portion 30 may be provided with the flat circular member 293 (see FIG. 62A) to advantageously provide additional sealing by flexing and bending against the starting flank of the thread of the coupler 12 or chamfer at the opening 16 of the coupler 12.
Referring to FIG. 71E, the arched portion 336 may be wide at the bottom portions 344 and narrow at the middle portion 346. The edge portions 348 of the arched wall 336 may be tapered.
Referring to FIGS. 71F-71G, the plug shown in FIG. 71D is shown attached to the coupler 12, which is embedded in the concrete structure 46. The top surface 29 of the plug is preferably disposed at the same level of the top concrete surface 48 so that the top edge 39 of the coupler 12 is situated below the top surface 48 of the concrete structure when the plug is removed after the concrete is cured to advantageously avoid having protrusions above the concrete surface that may interfere with laying down a other structures, such as a bottom plate of a stud wall, on the concrete surface 48. The vertical member 56 is advantageously flexible so as to bend from the vertical to the horizontal when hit by the blades of the concrete finishing equipment. The narrow middle portion 346 of the arched wall portion 336 and the space 338 below the arched wall portion 336 advantageously facilitates the bending of the vertical member 56. After the side forces hitting the vertical member 56 are removed, the vertical member 56 returns to its vertical position, as shown in FIG. 71G, to provide its locating function for the later removal of the plug. However, if the vertical member 56 were cut off during concrete finishing, the arched wall portion 336 may be located by breaking the thin layer of concrete which may be covering it with a tool, such as a hammer, since the arched wall portion 336 is flexible and will not support the thin layer of concrete when hit by the tool.
Referring to FIG. 71H, the tapered edge portions 348 of the arched wall portion 336 are shown.
Referring to FIG. 71I, the narrow middle portion 346 of the arched wall portion 336 flexes into the space 338 when the vertical member 56 is flexed to the horizontal.
It should be understood that the various features shown in a particular combination in an embodiment of the coupler, the cap, the plug and the anchor rod assembly are equally applicable and may be interchanged with the other features shown in another configuration of the coupler, the cap, the plug, and the anchor rod assembly to arrive at different configurations even though not specifically disclosed in combination with the other embodiments. For example, the upper portions of the plugs disclosed herein, such as flat, recessed or convex, solid or hollow, with or without the vertical members may be combined with any of the various embodiments of the plug portions disclosed herein, such as threaded or non-threaded, tapered or cylindrical, solid or hollow or tubular.
While this invention has been described as having preferred design, it is understood that it is capable of further modifications, uses and/or adaptations following in general the principle of the invention and including such departures from the present disclosure as come within known or customary practice in the art to which the invention pertains, and as may be applied to the essential features set forth, and fall within the scope of the invention or the limits of the appended claims.
Patent Application
20250052055
