COUPLER SYSTEM FOR REINFORCED CONCRETE

BACKGROUND

Concrete is a mixture of cement, water, and aggregates. Known for its strength, durability, low maintenance, energy efficiency, and relatively low cost, concrete is one of the most frequently used building materials used for constructing buildings, bridges, roads, sidewalks and other structures. In some structures, concrete is used in combination with reinforcement bars (herein, rebars). The combination of concrete and rebars is known as reinforced concrete and is widely used to mitigate the weak tension of concrete by distributing the tensile forces evenly across the structure and support heavy loads.

SUMMARY

Some embodiments of the invention provide a coupler system for concrete structures can include a coupler and a flange attachment. The coupler can include a first end that secures a first rebar at the first end of the coupler and an internal cavity with an opening at a second end of the coupler to receive a second rebar in an axial direction to be secured with grout within the internal cavity. The flange attachment can include one or more first protrusions that extend into the opening to secure the flange attachment to the coupler and a flange portion that extends radially, relative to the axial direction, beyond an outer diameter of the coupler, with a passage through the flange portion that is aligned with the opening of the coupler along the axial direction.

Some embodiments of the invention provide a method forming a concrete deck or other structure. The method can include securing a coupler system to a concrete form, securing a flange portion of a flange attachment of the coupler system to the concrete form, and securing the flange attachment to a coupler of the coupler system. The coupler can secure a first rebar at a first end of the coupler and can include an internal cavity with an opening at a second end of the coupler. The flange attachment can be secured the second end of the coupler so that a passage through the flange portion is aligned with the opening of the coupler along an axial direction. The method can further include pouring a first quantity of concrete over a first area so that the first quantity of concrete covers the first rebar and the coupler system. After the first quantity of concrete is set, the concrete form can be removed from the coupler system, so that the flange attachment remains attached to the coupler. A second rebar can be passed through the passage of the flange portion into the internal cavity of the coupler, and a second quantity of concrete can be poured over a second area so that the second quantity of concrete covers the second rebar. After the second quantity of concrete is set, grout can be added to the internal cavity to secure the second rebar within the coupler.

Some embodiments of the invention provide a method of forming a concrete deck or other concrete structure. A coupler system can be secured to a concrete form, including: securing a flange portion of a flange attachment of the coupler system to the concrete form, to secure the flange attachment to the concrete form; and extending one or more first protrusions of the flange attachment into an opening of a coupler of the coupler system. The one or more first protrusions can secure the coupler to the flange attachment with: a passage through the flange portion being aligned with the opening of the coupler along an axial direction, and the flange portion extending, relative to the axial direction, radially beyond an outer diameter of the coupler. With the flange portion secured to the concrete form to secure the coupler to the form via the flange attachment and the one or more first protrusions, and with the coupler securing a first rebar at a first end of the coupler, pouring a first quantity of concrete over a first area to cover the first rebar and the coupler system, including the flange attachment and the coupler. After the first quantity of concrete is set: the concrete form can be removed from the coupler system, with the flange attachment remaining secured to the couple, a second rebar can be passed through the passage and the opening of the coupler into an internal cavity of the coupler, and a second quantity of concrete can be poured over a second area adjacent to the first area, so that the second quantity of concrete covers the second rebar.

Some embodiments of the invention provide a coupler system for concrete structures. A coupler can secure a first rebar at a first end of the coupler and can include an internal cavity and an opening at a second end of the coupler that receives a second rebar in an axial direction into the internal cavity to secure the second rebar within the internal cavity. A flange attachment can be secured to the second end of the coupler. The flange attachment can include: one or more first protrusions that extend into the opening of the coupler to secure the flange attachment to the coupler. A flange portion can extend, relative to the axial direction, radially beyond an outer diameter of the coupler, and can include a passage through the flange portion that is aligned with the opening of the coupler along the axial direction.

Some embodiments of the invention provide a method of forming a concrete deck or other concrete structure. A coupler system can be secured to a concrete form. A radially-protruding flange portion of a flange attachment of the coupler system can be secured to the concrete form, to secure the flange attachment to the concrete form. A coupler of the coupler system can be secured to the flange attachment by resiliently engaging one or more first protrusions of the flange attachment with the coupler, within an opening of a coupler, to secure the coupler to the flange attachment. With the coupler system secured to the concrete form, a first quantity of concrete can be poured to cover the coupler system and a first rebar extending from the coupler system away from the concrete form. After the first quantity of concrete is set: the concrete form can be removed from the coupler system, with the flange attachment remaining secured to the coupler, a second rebar can be passed through the flange attachment and the opening of the coupler into an internal cavity of the coupler, and a second quantity of concrete can be poured adjacent to the set first quantity of concrete to cover the second rebar.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of embodiments of the invention:

FIG. 1A is a schematic view of a concrete installation with a pour strip;

FIGS. 1B and 1C are schematic views of a concrete installation and coupler system according to an example of the present disclosure;

FIG. 2 is a front isometric view of an example flange attachment of the coupler system of FIGS. 1B and 1C;

FIG. 3 is a front isometric view of a coupler system secured to a concrete form, including a coupler that is secured to the flange attachment of FIG. 2;

FIG. 4 is a cross-sectional view of the coupler system of FIG. 2, the coupler system detached from the concrete form;

FIG. 5 is a cross-sectional detailed view of the coupler system of FIG. 2;

FIG. 6 is a front isometric view of another configuration of a flange attachment of the coupler system of FIGS. 1B and 1C;

FIG. 7 is a right elevational view of the flange attachment of FIG. 6;

FIG. 8 is a front elevational view of the flange attachment of FIG. 6 secured to a coupler;

FIG. 9 is a front isometric view of another configuration of a flange attachment of the coupler system of FIGS. 1B and 1C;

FIG. 10 is a cross-sectional detailed view of the flange attachment of FIG. 9;

FIG. 11 is a front isometric view of another configuration of a flange attachment;

FIG. 12 is front isometric view of an example coupler system of FIGS. 1B and 1C secured to a concrete form, including a coupler that is secured to the flange attachment of FIG. 11;

FIG. 13 is a cross-sectional view of the coupler system of FIG. 12;

FIG. 14 is a rear isometric view of a coupler system of FIG. 2 including an adhesive seal member;

FIG. 15 is a flow chart illustrating a method of forming a concrete structure, including with configurations of the coupler system of FIGS. 1B and 1C;

FIGS. 16 and 17 are isometric first-and second-side views of another configuration of a flange attachment of the coupler system of FIGS. 1B and 1C;

FIG. 18 shows isometric first-and second-side views of a seal member for use with the flange attachment of FIGS. 16 and 17;

FIG. 19 shows isometric first-and second-side views of another seal member for use with the flange attachment of FIGS. 16 and 17; and

FIGS. 20 and 21 are isometric first-and second-side views of another configuration of a flange attachment of the coupler system of FIGS. 1B and 1C.

DETAILED DESCRIPTION

Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives and fall within the scope of embodiments of the invention.

In some construction operations, a large concrete slab can be formed by intentionally leaving a relatively large gap between two smaller concrete slabs. The gap allows the two smaller concrete slabs to shrink freely, thus reducing the final large (multi-pour) slab's tendency to crack. After the smaller slabs have cured, the gap is filled with additional concrete (i.e., a “pour strip”) to form the large concrete slab. However, closing the pour strips in this manner can be costly, including because formwork, shoring, and back-shoring must stay in place for an extended time, and pouring and other required operations can be time consuming.

Embodiments of the disclosed invention can provide improved systems and methods for forming concrete structures (e.g., poured concrete decks), including for large slabs that are formed from multiple smaller slabs. In some examples, a coupler can include an attachment mechanism (e.g., a protruding flange) to allow attachment to a concrete form for cast-in-place (or other) floors or walls. For example, a coupler for a first rebar to be included in a first pour can be attached to a flange attachment, and the flange attachment can be secured to a concrete form used for the first pour to form a first concrete slab. With this arrangement, for example, after the first slab is set/cured and the form is removed, the flange attachment can remain in place on the coupler.

In some examples, the coupler can then receive a second rebar to be included in a second concrete slab. For example, the second rebar can be slidingly received through a seal structure on the flange attachment that can also help to prevent uncured concrete from the second concrete slab from infiltrating the. Correspondingly, after a second pour to form the second concrete slab, movement of the second rebar due to shrinkage of the second concrete slab can be accommodated by the coupler and the flange attachment (e.g., via sliding movement of the second rebar through the flange attachment and within the coupler). Further, the flange attachment can prevent material from the second pour from entering into the coupler and thereby protect the ability to later inject grout into the coupler to fully secure the second rebar to the first. Once the second slab is set/cured, a relatively small amount of curable material (e.g., grout) can be poured into the relatively small gap between the first and second slabs to complete the larger structure.

In some examples, flange attachments can have various geometries to engage with a coupler, can include various sealing arrangements, or can exhibit various other improvements. In this regard, features discussed below with respect to particular examples can also be used with other examples, including as additions to or substitutions for particular other components.

Conventional systems do not provide for particularly efficient methods of uniting two separate concrete pours into a larger structure. FIG. 1A illustrates a concrete structure 100 including a first slab 102 bounded by a first concrete form 104 and formed by a first pour, and a second slab 106 bounded by a second concrete form 108 and formed by a second pour. The first and second concrete form 104, 108 contain and shape the first and second slabs 102, 106 until the concrete hardens and achieves a desired strength. However, during the hardening of the concrete, the first slab 102 and the second slab 106 experience shrinking which may tend to cause cracking if not properly addressed. Accordingly, between the first concrete form 104 of the first slab 102 and the second concrete form 108 of the second slab 106, a gap 110 for a pour strip is formed to accommodate the shrinkage of the first and second slabs 102, 106. In some examples, a width of the pour strip gap 110 (i.e., between the first and second slabs 102, 106) may be between about 4 inches and 8 inches. In some examples, the pour strip gap 110 may include rebars 112 that extend between the first slab 102 and the second slab 106. After the first and second slabs 102, 106 are cured, and the first and second concrete form 104, 108 are removed, concrete is poured into the gap 110 to connect the first and second slab 102, 106, to form a monolithic concrete structure.

Generally, the features discussed below can collectively help to reduce the cost and time for connecting separate two separate concrete structure, including as an improvement or replacement for the general approach discussed relative to FIG. 1A. Other benefits will be also apparent to those of skill in the art in view of the detailed discussion below. The concepts described herein can be practiced in various concrete structures (e.g., concrete walls or slabs) for various purposes.

As an alternative to the approach of FIG. 1A, for example, some example of the disclosed technology can be used to implement a concrete installation as generally illustrated in FIG. 1B and 1C. In this regard, example configurations as discussed for FIGS. 2 through 21 can be or provide particular implementations of the structures and operations illustrated and discussed relative to FIG. 1B and 1C. Accordingly, for example, unless otherwise indicated, discussion of FIGS. 1B and 1C applies equally to similarly named or utilized components in the various examples of the remaining figures, and vice versa.

As shown in FIG. 1B, to form a concrete installation 100′, a flange attachment 114 (or other flange structure) of a coupler system 118 can be secured to the concrete form 104, so that the flange attachment 114 supports an attached rebar coupler 116 of the coupler system 118, relative to the concrete form 104. A first rebar 112A can be secured to the coupler 116, to extend away from the form 104 (e.g., can be secured with a threaded or other connection, on an opposite side of the coupler 116 from the form 104). Thus arranged, for example, the coupler 116 and the rebar 112A can be secured to the form 104 by the flange attachment 114 (e.g., without separate fasteners to secure the coupler 116 to the flange attachment 114). Further, the flange attachment 114 may be seated against the form 104 to block concrete from infiltrating the interior of the coupler. Accordingly, for example, as shown in dotted relief in FIG. 1B, a first quantity of concrete 102′ can be poured over the coupler 116, the flange attachment 114, and the rebar 112A, then cured.

Once the concrete 102′ has suitably cured (as shown in solid relief in FIG. 1C), the form 104 can be removed, leaving the flange attachment 114 secured to the coupler 116 and embedded in the cured concrete 102′, but with the flange attachment 114 at least partly exposed at the edge of the concrete 102′ that corresponds to the form 104. Accordingly, a second rebar 112B can then be inserted through the flange attachment 114 (e.g., and through a seal member secured thereto) and into the interior of the coupler 116. As shown in dotted relief in FIG. 1C, a second quantity of concrete 106′ can then be poured over the rebar 112B, adjacent to the cured concrete 102′ (e.g., without the use of the second form 108, as discussed relative to FIG. 1A), and then allowed to cure.

Due to shrinkage of the concrete 106′ during curing, a small gap 110′ may thus result between the masses of cured concrete 102′, 106′. However, due to the use of the coupler system 118 as generally discussed above, the gap 110′ may be significantly smaller than the gap 110 as employed during pour strip construction (see FIG. 1A). Accordingly, for example, the gap 110′ can be filled with a relatively narrow pour of grout 119 to complete the combined concrete installation 100′ (e.g., rather than being filled with concrete formulated for slab formation, with corresponding increases in time and expense, as generally discussed above).

Coupler assemblies according to the disclosed technology can generally include a flange structure that allows a rebar coupler (e.g., a grouted coupler) to be temporarily secured to a concrete form for a first concrete pour. After the first pour has cured and the concrete form has been removed, the flange structure can remain with the coupler, embedded in a first slab of concrete, but with an end portion exposed to receive rebar from a second slab into the coupler. In some examples, the flange structure can thus prevent concrete from a second pour from entering the coupler (in combination with the rebar from the second slab), while also allowing the rebar from the second slab to move within the coupler (e.g., to accommodate shrinkage of the second slab during curing).

In some examples, a flange structure can be formed as a flange attachment that can be formed separately from and then secured to a rebar coupler (e.g., with the flange attachment and the coupler separately, integrally formed). For example, as a particular implementation of the flange attachment 114 discussed above, FIG. 2 illustrates a flange attachment 120 that includes a flange portion 126 and an aperture 124 through the flange portion 126. The flange attachment 120 is integrally formed in the illustrated example, although other approaches for manufacturing are possible. The aperture 124 defines a passage for rebar with an axial direction A1, and the flange portion 126 of the flange attachment 120 extends radially outwardly relative to the aperture 124 (i.e., with a radial direction defined relative to the axial direction A1). In the illustrated embodiment, a raised portion 128 that is coaxial with the aperture 124, is positioned between the aperture 124 and the flange portion 126. In some examples, the raised portion 128 may include a thickness that is equivalent to a thickness of the flange portion 126. In some examples, the thickness of the raised portion 128 may be different from the thickness of the flange portion 126. Further, in some embodiments, the raised portion 128 can be absent between the flange portion 126 and the aperture 124 or can be differently configured than shown.

As also generally noted above, the flange portion 126 includes a radially protruding structure that define a peripheral shape of the flange attachment 120 (e.g., a square shape with corners 130, in the example shown). As illustrated, the flange attachment 120 has a rectangular (e.g., square) perimeter, with a top wall 132, a bottom wall 134, and side walls 136, 138 that are substantially perpendicular to the top and bottom walls 132, 134. In other examples, other configurations are possible, including flange attachment 120 with different numbers or orientations of walls, corners, etc. Further, as also detailed below, a perimeter of a flange attachment 120 may be interrupted by various protrusions (e.g., to be embedded in surrounding concrete).

Around the aperture 124, the flange attachment 120 includes first protrusions 142, and second protrusions 144 extends in a similar direction (e.g., away from a first contact surface 146 that is opposite of a second contact surface 148). As illustrated in FIG. 2, the first protrusions 142 extend substantially perpendicular from a periphery 150 of the aperture 124, away from the first contact surface 146. In some examples, the first protrusions 142 are arranged circumferentially about the axial direction, extending integrally from the periphery 150 of the aperture. In some examples, the first protrusions 142 are spaced equidistantly around the periphery 150 of the aperture 124. In the illustrated example, three sets of first protrusion 142 extend from the periphery 150 of the aperture 124 for a common first axial distance D1 (i.e., as measured in the axial direction between proximal and distal ends 154, 156), although other configurations are possible.

Also in the illustrated example, curved tabs 152 alternate with the first protrusions 142 alternates around the periphery 150 of the aperture 124 to form a collet-style passage. In some example, the curved tabs 152 can function as gripping tabs to help secure additional components, provide alignment guides (e.g., for inserted rebar), or provide other structural support (e.g., to orient, secure, or strengthen a seal member).

In some examples, protrusions on a flange structure can include contours to help engage with an inner diameter or other portion of a rebar coupler (e.g., internally to the coupler, at an open end of an internal cavity of a grouted coupler). For example, as shown in FIG. 2, various retention tabs 158 are formed to project radially outwardly between the distal ends 156 and the proximal ends 154 of the first protrusions 142. Thus, although the protrusions 142 are formed as planar tabs in the illustrated example, the retention tabs 158 are arranged on the protrusions 142 so as to be engageable with a circular profile on an inner diameter of a coupler (as further discussed below). In other embodiments, different numbers or arrangements of retention tabs (or other retention structures) can be included.

The second protrusion 144 includes a proximal region 164 that connects the second protrusion 144 with the flange portion 126 of the flange attachment 120, and a distal region 166 that is spaced apart from the proximal region 164 by a second axial distance D2. Generally, the protrusions 144 thus extend by the distance D2 away from the contact surface 146, in the same direction as the protrusions 142 but at a larger radial spacing away from the aperture 1124. Accordingly, the protrusions 144 can provide features on the flange attachment 120 that extend to the outside of an attached coupler and can thus become directly embedded in surrounding concrete. In this regard, for example, the protrusions can include hooked or other curved or angled geometry to allow for more secure engagement with surrounding cured material.

The first protrusions 142 and the second protrusions 144 described above and below may be present in different quantities (e.g., set of first protrusions or second protrusions). In the illustrated example, three sets of first protrusions 142 extend from the aperture 124 and four sets of second protrusions extends from the perimeter 162 of the flange portion 126 between the corners 130. The triangular arrangement of the first protrusions may be particularly beneficial because the triangular arrangement can offer good stability, particularly when clamping cylindrical or round objects (e.g., coupler). However, different arrangements and quantities of first and second protrusions 142, 144 are possible according to various applications and the shape of the coupler.

The flange attachment 120 can generally be configured to be temporarily attached to a concrete form (e.g., a wooden form) and can correspondingly generally include at least one attachment feature. In the illustrated example, the flange attachment 120 includes holes 170 that are disposed adjacent to the corners 130 of the flange attachment 120. For instance, the holes 170 can be pre-formed fastener holes to secure the flange attachment 120 to a concrete form (see 122 of FIG. 3). In some examples, the holes 170 may be surrounded by embossments 172 that are raised from the first contact surface 146 (e.g., to provide additional strength around the holes 170). As further illustrated in FIG. 3, the holes 170 can receive fasteners (e.g., screws, nails) to secure the flange attachment 120 to a concrete form. In other examples, other fastening mechanisms are possible, including adhesives or the like. In some examples, as also noted above, although fasteners may be used to secure the flange attachment 120 to a concrete form, separate fasteners may not be required to secure the flange attachment 120 to a coupler.

Referring now to FIG. 3, a coupler system 200 for concrete structures is shown, attached to a concrete form 122 to allow a concrete pour that will embed the coupler system 200 within the concrete. The coupler system 200 is a particular example of the coupler system 118 and discussion of the coupler system 118 above thus also applies to the coupler system 200, unless otherwise indicated (and vice versa). In the illustrated example, the coupler system 200 includes a coupler 202 that is secured to the flange attachment 120 about an end of the coupler 202, and the flange attachment 120 is secured to (and secures the coupler 202 to) the concrete form 122. For example, as shown, nails or other fasteners can be driven through the flange attachment 120 to secure the flange attachment 120 to the form 122.

The coupler 202 includes a first end 204, a second end 206, and an internal cavity 208 (see FIG. 4). The first end 204 of the coupler 202 is configured to receive and secure a first rebar 210 (e.g., with a threaded connection) and the second end 206 of the coupler 202 includes an opening 212 (see FIG. 4) that is in communication with the internal cavity 208. The opening 212 defines an inner diameter ID that is smaller than a corresponding outer diameter OD of the coupler 202. The coupler 202 also includes a plurality of grout ports 214 to allow filling of grout into the coupler 202 after a concrete pour (as shown, with grout tubes 216).

Referring now to FIG. 4 a cross-sectional view of the coupler system 200 is shown. The flange attachment 120 is secured to the second end 206 of the coupler 202 such that the first protrusions 142 of the flange attachment 120 extends through the opening 212 of the coupler 202, into the internal cavity 208, to secure the flange attachment 120 to the coupler 202. More specifically, referring also to FIG. 5, the retention tabs 158 of the first protrusions 142 catch on a peripheral flange 218 of the coupler 202 that is adjacent to the opening 212 (e.g., to provide snap-engagement with the coupler 202). In other words, the one or more first protrusions 142 engage at the inner diameter ID of the opening 212 in the example shown, although engagement at other locations within the cavity 208 is also possible.

Accordingly, the aperture 124 of the flange portion (and corresponding passage for rebar) is aligned with the opening 212 of the coupler along the axial direction A1. Additionally, the flange portion 126 extends beyond the outer diameter OD of the coupler 202 to provide a hard stop for the coupler 202 and to expose sufficient area of the radially protruding material to allow attachment to the concrete form 122.

As described above, the raised portion 128 is formed between the flange portion 126 and the aperture 124 along the first contact surface 146. Still referring to FIG. 5, along the second contact surface 148, a corresponding depressed region 220 is formed to receive a seal member 222 (e.g., polymeric gasket or other flexible barrier). Referring to FIG. 5, the seal member 222 is pushed into the depressed region 220 such that the seal member 222 is contained within the depressed region 220. In some examples, including as shown in FIG. 5, protrusions on a seal member can engage with corresponding openings (or other features) on a flange structure, to further secure the seal member to the flange structure. In other examples, a seal member can be otherwise secured to at least partially cover the opening 212.

In the illustrated example, the seal member 222 is configured so that the seal member 222 at least partially covers the aperture 124 of the flange attachment 120. However, the seal member 222 includes a slot 226 (or other opening) that can receive a second rebar 224, into the second end 206 of the coupler 202, in the axial direction A1. Accordingly, the seal member 222 can allow the rebar 224 to be aligned to be grouted into place within the coupler 202, while preventing concrete of a corresponding (subsequent) concrete pour from also entering the coupler 202.

Referring now to FIG. 6, a flange attachment 320 is shown as another particular implementation of the flange attachment 114 discussed above. Generally, the flange attachment 320 is an alternative configuration of the flange attachment 120. To that end, features of the flange attachment 320 include reference numbers that are generally similar to those used in FIG. 2 and discussion of similar numbers or terminology above also applies below unless otherwise indicated. For example, the flange attachment 320 includes an aperture 324 and a flange portion 326 that extends radially relative to the axial direction A2.

Unlike the flange attachment 120 of FIG. 2, first protrusions 342 of the flange attachment 320 define circumferentially protruding structures as snap wings 380, including a first end 382 and a second end 384 opposite of the first end 382. Further, the perimeter 362 of the flange attachment 320 does not include second protrusions 344 disposed between corners 330 of the flange attachment 320. However, in some examples, the second protrusions 344 can be incorporated into the flange attachment 320 about the perimeter 362 of the flange attachment 320. Further, as generally noted above, one or more other features of the configuration illustrated for the flange attachment 120 can be included in addition to or as a substitute for the features illustrated for the flange attachment 320 (and vice versa).

Referring to FIG. 7, the first protrusion 342 extends substantially perpendicular to a first contact surface 346. The first end 382 and the second end 384 of the snap wings 380 include, respectively, a sloped bottom surface 394 that is configured to engage with the peripheral flange 218 of the coupler 202 (see, e.g., FIG. 5).

Referring to FIG. 8, first end 382 and the second end 384 is eccentric to the inner diameter ID of the coupler 202 such that the first and second ends 382, 384 bend inward to engage with the coupler 202. For example, the first end 382 may include a first inflexion point and the second end 384 may include a second inflexion point that abut to the inner diameter ID of the coupler 202 such that the snap wing 380 latches to the peripheral flange 218 through an interference fit.

Referring now to FIG. 9, a flange attachment 420 is shown as another particular implementation of the flange attachment 114 discussed above. Generally, the flange attachment 420 is an alternative configuration of the flange attachments 120, 320. To that end, features of the flange attachment 420 include reference numbers that are generally similar to those used FIG. 2 and discussion of similar numbers or terminology above also applies below unless otherwise indicated. For example, the flange attachment 420 includes an aperture 424 and a flange portion 426 that extends radially relative to the axial direction A3. As generally noted above, one or more other features of the configuration illustrated for the flange attachments 120, 320 can be included in addition to or as a substitute for the features illustrated for the flange attachment 420 (and vice versa).

The flange attachment 420 includes first protrusions 442 and curved tabs 452 that extends substantially perpendicularly from the aperture 424 of the flange attachment 420. The first protrusions 442 extend outwardly by a first length L1 and the curved tabs 452 extend outwardly by a second length L2. In the illustrated example, referring to FIG. 9, the first length L1 of the first protrusions 442 is greater than the second length L2 of the curved tabs 452. The first protrusions 442 and the curved tabs 452 are disposed circumferentially equidistant from another. In other words, the first protrusions 442 and the curved tabs 452 form a collet shape that is equally spaced by gaps 482. Additionally, in the illustrated example, the flange attachment 420 does not include second protrusions that are disposed about the perimeter 462 of the flange attachment 420 between the two adjacent corners 450. However, as appropriate, second protrusions (e.g., similarly the protrusions 144 of FIG. 2) can be added between the respective corners 450 of the flange attachment 420, or at other locations.

The flange attachment 420 also includes a plurality of holes 484 are disposed circumferentially about the axial direction A4 of the flange attachment 420. The holes 484, for example, can receive protrusions on a seal member (e.g., protrusions 228 on the seal member 222 of FIG. 5) to secure the seal member to the flange attachment 420.

Referring now to FIG. 10, the first protrusion 442 and the curved tabs 452 are disposed concentrically along the aperture 424 such that a clamp wing 486 of the first protrusion 442 abuts radially within the inner diameter ID of the coupler 202 while the curved tabs 452 provide alignment of the flange attachment 420. Accordingly, the aperture 424 of the flange attachment 420 can be coaxial with the opening 212 of the coupler 202. Similar to the flange attachment of FIG. 6, the clamp wing 486 can push against the inner diameter ID of the coupler 202 to provide an interference fit such that the clamp wing 486 is retained by the peripheral flange 218 of the coupler 202.

In some examples, the flange attachments 120, 320, 420 of FIGS. 2, 6, and 9 can be efficiently and reliably manufactured by stamping metal sheets. For example, the flange attachments 120, 320, 420 (or others discussed herein) can be manufactured using carbon steel, stainless steel, spring steel, or metal alloys which can provide high yield strength, elasticity, and resilience. In some examples, different components of the flange attachments 120, 320, 420 can be manufactured using the same or different one or more materials.

In some examples, flange attachments as discussed herein can be made from spring steel to provide resilience to provide snapping features to the first protrusions 142, 342, 442. However, other approaches are possible. For example, various flange attachment can be manufactured using plastic molding or other known approaches for forming composite materials (e.g., additive manufacturing). For example, the flange attachment can be manufactured using various polymers such as, but not limited to, polyethylene, polypropylene, polyvinyl chloride, polystyrene, polycarbonate, polyamide, polyethylene vinyl acetate or the like.

In this regard, for example, FIG. 11, shows a flange attachment 520 that can be integrally formed from non-metallic (or other) material. Generally, the flange attachment 520 is an alternative configuration of the flange attachments 120, 320, 420. To that end, features of the flange attachment 520 include reference numbers that are generally similar to those used in FIG. 2 and discussion of similar numbers or terminology above also applies below unless otherwise indicated. For example, the flange attachment 520 includes an aperture 524 and a flange portion 526 that extends radially relative to the axial direction A4. Further, as generally noted above, one or more other features of the configuration illustrated for the flange attachment 520 can be included in addition to or as a substitute for the features illustrated for the flange attachments 120, 320, 420 (and vice versa).

The flange attachment 520 may be formed from molded or printed plastic material. In this regard, for example, the flange attachment 520 may include walls 532, 534, 536, 538 that are thicker than the walls 132, 132, 136, 138 of flange attachment 120 of FIG. 2 (e.g., stamped from sheet metal) in order to compensate for the difference in material properties (e.g., modulus of elasticity, toughness) between sheet metal and plastic. Similarly, second protrusions 544 extending between the two adjacent corners of the flange attachment 520 may be thicker than the second protrusions 144 of FIG. 2. Further, the buttresses 572 around the holes 570 can be provided of various shapes and thicknesses.

In the illustrated example, semi-circular structures define the first protrusions 542, including a first set 580 of first protrusion 542 that is defined by an upper semi-circular protrusion, and a second set 582 of first protrusion 542 that is defined by a lower semi-circular protrusion, with a gap 584 that extends between the first set 580 and the second set 582 of the first protrusions 542. In particular, the first protrusions 542 include a plurality of barbs 586 (e.g., formed as ribs) or other protrusions that can aid in alignment of a rebar that is inserted through the aperture 524 that is defined by the first protrusions 542.

Referring now to FIGS. 12 and 13, attachment of a coupler system 600 to a concrete form is shown, in a process similar to that described for the coupler system 200 of FIGS. 3 and 4. In this regard, the coupler system 600 is also a particular example of the coupler system 118 (and 200) and discussion of the coupler systems 118, 200 above thus also applies to the coupler system 600, unless otherwise indicated. To that end, features of the coupler system 600 include reference numbers that are generally similar to those used in FIG. 3. For example, the coupler system 600 includes a coupler 602 being coupled to the flange attachment 520 to be secured thereby to the concrete form 122.

Referring to FIG. 13, a seal member 612 is retained within a flange portion 526 of the flange attachment 520 along the second contact surface 548. For example, seal retention features can be molded in a circumferential array around the aperture 524 of the flange attachment 520. Accordingly, one or more protrusions 628 of the seal member 612 can be inserted into corresponding seal retention features (e.g., apertures 634, as shown in FIG.) to secure the seal member 612 in place on the flange attachment 520. Further, the seal member 612 may include a plurality of flaps 630 that are disposed circumferentially about the axial direction A5. For example, cut slits 632 (or otherwise structured openings) can be formed between adjacent flaps 630 to assist a second rebar from entering the coupler 602 from a second end 606.

Referring now to FIG. 14, in some embodiments, the seal member 712 can be an adhesive seal member (e.g., to be adhesively attached to the second contact surface of the flange attachments 120, 320, 420, 520). The seal member 712 may include a hole 750 to splinter open when a rebar is inserted thereof, or other pre-formed or formable opening structure). In some examples, the hole 750 may be larger than the apertures 124, 324, 424, 524 of the flange attachments 120, 320, 420, 520. In some examples, the hole 750 may be smaller than the apertures 124, 324, 424, 524 of the flange attachments 120, 320, 420, 520 to prevent fluid exchange through the seal member 712.

Referring now to FIG. 15, a method 800 of forming a concrete structure (e.g., concrete deck) using a coupler system is shown. The method 800 is discussed in particular relative to the flange attachment 120 and the coupler 202, but can be similarly applied—in whole or in part—relative to other coupler systems with flange structures as variously disclosed herein (e.g., other coupler assemblies with a coupler and a flange attachment as discussed above and below).

In the illustrated example, a first operation 810 can include securing a coupler system (e.g., the system 200) to the concrete form 122. For example, the flange attachment 120 can be secured to the coupler 202, and the flange portion 126 of the flange attachment 120 can be secured to the concrete form 122 (e.g., with nails, as shown in FIG. 3). The coupler 202 can also be secured to the first rebar 210 at the first end 204 of the coupler (e.g., after being secured to the flange attachment 120, for ease of handling).

A second operation 820 can include pouring a first quantity of concrete over a first area so that the first quantity of concrete covers the first rebar 210 and the coupler system 200. Thus, the coupler system 200 can be embedded in the cured first quantity of concrete. For example, as noted above, the second protrusions 144 of the flange attachment 120 can receive and retain concrete that is poured around an outside of the coupler 202. As the concrete is set and cured, the second protrusion 144 may thus provide anchorage for the flange attachment 120 within the first quantity of concrete.

After the first quantity of concrete is set, a third operation 830 can include removing the concrete form 122 from the coupler system 200, so that the flange attachment 120 remains attached to the coupler 202. For example, referring back to FIG. 4, the nails that secure the flange attachment 120 to the concrete form can be removed from the form 122 or broken, etc. Thus, the concrete form 122 can be detached from the flange attachment 120. Further, upon removal of the form 122, the flange attachment 120 and the coupler 202 may remain secured together within the set concrete (e.g., with the second protrusions 144 securing the flange attachment 120 in particular against removal from the cured concrete as the form 122 is removed).

A fourth operation 840 can include passing the second rebar 224 through the aperture 124 of the flange portion 126 into the internal cavity 208 of the coupler 202. In some embodiments, the seal member 222 can be added prior to passing a second rebar 224 through the aperture 124 of the flange portion 126 (e.g., included before the first concrete pour). Thus, for example, the second rebar 224 can be passed through the aperture 124 to be secured within the coupler 202, while the seal member 222 and the rebar 224 can collectively cover the aperture 124 to prevent ingress of concrete (e.g., from a later pour).

A fifth operation 850 can include pouring a second quantity of concrete over a second area so that the second quantity of concrete covers the second rebar 224. During this pour, for example, and subsequent curing, the seal member 222 provided around the aperture 124 of the flange attachment 120 can help to prevent the second quantity of concrete from entering the internal cavity 208 of the coupler 202. Thus, for example, the second rebar 224 may move somewhat freely within the coupler 202 in response to the expected shrinkage of the concrete of the second quantity during curing.

After the second quantity of concrete is appropriately set, a sixth operation 860 can include adding grout into the internal cavity 208 through a grout port 214 or grout tubes 216 to secure the second rebar 224 with the coupler 202. Thus, for example, the second rebar 224 can be secured by the grout in a final position that accommodates the cured dimensions of the second pour of concrete.

In some examples, as mentioned above, a gap between the cured pours may result, including from a first shrinkage of the first quantity of concrete (e.g., between the flange attachment 120 and the form for a first pour, and between the flange attachment 120 and the concrete of a second, adjacent pour). In such cases, additional grout can be poured to fill the corresponding gap(s), between the first or second quantities of concrete, including so as to fully surround any exposed parts of the coupler 202 in some cases. In some examples, a gap to be thus filled may be less than approximately 1 inch in width or between 0.25 and 2.5 inches, inclusive. Thus, for example, this approach can easily accommodate use of grout rather than a conventional concrete pour strip.

FIGS. 16 and 17 illustrate a flange attachment 920 that includes an aperture 924 and a flange portion 926 and is another particular example of the flange attachment 114 of FIGS. 1B and 1C. Accordingly, discussion of similar numbers or terminology with respect to flange attachments above also applies below unless otherwise indicated. The flange attachment 920 is integrally formed in the illustrated example, although other approaches for manufacturing are possible. The aperture 924 defines a passage for rebar (not shown) with an axial direction A1, and the flange portion 926 of the flange attachment 920 extends radially outwardly relative to the aperture 924, with a radial direction defined relative to the axial direction A1. In the illustrated embodiment, a raised portion 928 that is coaxial with the aperture 924 is positioned between the aperture 924 and the flange portion 926.

The flange portion 926 includes a radially protruding structure that defines a peripheral shape of the flange attachment 920 (e.g., a square shape in the example shown). In other examples, other configurations are possible, including with a different overall profile, different arrangements of protruding structures, etc.

Around the aperture 924, the flange attachment 920 includes first protrusions 942, and second protrusions 944 extending in a similar direction. In particular, the first protrusions 942 are arranged around a periphery of the aperture 924, in a regular circumferential array (e.g., extending integrally from the periphery of the aperture 924). As shown, five of the first protrusions 942 can be included with equidistant spacing, although other numbers or arrangements are possible. Generally, the protrusions 942 can be configured for snap-fit or other engagement with an interior surface of a coupler (e.g., as also generally described above). In this regard, for example, the illustrated configuration of the first protrusions 942 includes a cantilevered, convolute profile with radially-inwardly angled free ends. Accordingly, the protrusions 942 can be easily aligned for insertion into an open end of a coupler, to be seated in resilient engagement with the coupler at outwardly concave portions 942A.

In the illustrated example, the second protrusions 944 are connected at and extend from select side edges of the flange attachment 920, spaced radially (and laterally) apart from the aperture 924. Generally, the second protrusions 944 can be configured to be embedded in concrete that surrounds the flange attachment 920 (e.g., as also generally discussed above) and can accordingly include profiles configured to effectively engage with set concrete (e.g., with bends, convolute sections, protrusions outside the axially projected footprint of the flange portion 926, etc.). For example, as illustrated, the second protrusions 944 include laterally outwardly extending distal flanges 966.

Also in the illustrated example, curved tabs 952 alternate with the first protrusions 942 alternates around the periphery of the aperture 924 to form a collet-style passage. In some example, the curved tabs 952 can function as gripping tabs to engage additional components, provide alignment guides (e.g., for inserted rebar), or provide other structural support (e.g., to orient, secure, or reinforce a seal member).

As also similarly described above, the flange attachment 920 can generally be configured to be temporarily attached to a concrete form (e.g., a wooden form) and can correspondingly include at least one attachment feature. In the illustrated example, the flange attachment 920 includes holes 970 that are disposed adjacent to the corners of the flange attachment 920. In particular, the holes 970 are formed with keyhole profiles (e.g., with a narrower portion that opens into a wider portion). This configuration, for example, can allow installers to stage the flange attachment 920 for installation by hanging the flange attachment 920 from a first fastener (not shown) through a first of the holes 970, then adjusting the flange attachment 920 to a final (or other staging) position before installing additional fasteners and then, as appropriate, attaching a coupler (e.g., the coupler 202, as discussed above).

Generally, the flange attachment 920 is similar to the flange attachment 120 and discussion above regarding the flange attachment 120 thus generally also applies to similar features on the flange attachment 920. Correspondingly, discussion above regarding installation of the flange attachment 120 onto a coupler or onto a concrete form, and other related operations, also generally applies to the flange attachment 920.

Also shown in FIGS. 16 through 18, a seal member 1022 generally similar to the seal member 222 of FIG. 5 (e.g., a polymeric gasket) can be secured to the flange attachment 920. In some examples, including as shown in FIG. 16, protrusions 1024 on the seal member 1022 can engage with corresponding attachment openings on a flange attachment to further secure the seal member 1022. For example, as shown in FIG. 16 the protrusions 1024 can be received in attachment openings formed as slots 946, circumferentially distributed around the raised portion 928, with the seal member 1022 correspondingly seated within a recess defined by the raised portion 928.

As installed, the seal member 1022 at least partially covers the aperture 924 of the flange attachment 920. However, the seal member 1022 also includes an opening 1026 that can receive rebar (not shown) that passes through the flange attachment 920. Accordingly, the seal member 1022 can allow the rebar to be aligned to be grouted into place within a coupler, while preventing concrete of a corresponding (subsequent) concrete pour from also entering the coupler.

In some examples, a seal member can include other features, including various reinforcement features to support securement to a flange attachment or support of a received rebar. For example, the seal member 1022 can include a protruding central boss 1028 that is received through the aperture 924, as illustrated in FIGS. 16 and 18, in particular. As shown in FIG. 18, reinforcing ribs can also be provided. For example, in the illustrated configuration, a ring rib 1030 surrounds the opening 1026, with buttress ribs 1032, 1034 extending radially from the ring rib 1030 on opposing (axial) sides of the seal member 1022. In some examples, the buttress ribs 1034 on a concave side of the central boss 1028 can extend over a full depth of the central boss 1028, at least in part. In some examples, ribs can extend to the outside of the central boss 1028 for further structural support (e.g., as shown in FIG. 18). As generally noted above, the ribs 1030, 1032, 1034 can help to provide improved resiliency of the seal member 1022 overall as well as improved support of a rebar received through the opening 1026. Thus, for example, a rebar received through the opening 1026 can be effectively prevented from sagging into a misaligned orientation relative to the corresponding coupler.

In some examples, particular seal members can be configured for particular sizes of rebar. For example, a seal member 1022A as shown in FIG. 19 is generally similar to the seal member 1022, including with an opening 1026A, protrusions 1024A and ribs 1030A, 1032A, 1034A, and can thus be similarly employed. However, the opening 1026A is sized for a smaller rebar than the opening 1026. Accordingly, for example, the seal members 1022A, 1022 can be selectively implemented with the same or similar design of a flange attachment to selectively accommodate installations with different sizes of rebar.

FIGS. 20 and 21 illustrate another flange attachment 1120 and seal member 1122 as another particular example of the flange attachment 114 of FIGS. 1B and 1C. Accordingly, discussion of similar numbers or terminology with respect to flange attachments above also applies below unless otherwise indicated. As illustrated, the flange attachment 1120 and seal member 1122 are configured similarly to the flange attachment 1020 and the seal member 1022 of FIGS. 16 and 17, and discussion of that example thus also applies in particular to FIGS. 20 and 21. However, first protrusions 1142 of the flange attachment 1120 may be somewhat more flexible than first protrusions 1042 of the flange attachment 1020 to allow for easier attachment to a coupler. For example, as shown in FIG. 20 in particular, cut-outs 1160 that define the first protrusions 1142 can bend to overlap circumferentially with the corresponding first protrusion 1142, thereby providing a more flexible necked-down connection between the first protrusions 1142 and the remainder of the flange attachment 114.

Thus, examples of the disclosed technology can provide improved systems and methods for multi-pour concrete constructions. For example, some configurations can allow grouted couplers to be used on adjacent post-tensioned concrete pours, and may avoid the time-consuming and expensive requirements of conventional pour strip approaches.

In some implementations, devices or systems disclosed herein can be utilized, manufactured, installed, etc. using methods embodying aspects of the disclosed technology. Correspondingly, any description herein of particular features, capabilities, or intended purposes of a device or system should be considered to disclose, as examples of the disclosed technology a method of using such devices for the intended purposes, a method of otherwise implementing such capabilities, a method of manufacturing relevant components of such a device or system (or the device or system as a whole), and a method of installing disclosed (or otherwise known) components to support such purposes or capabilities. Similarly, unless otherwise indicated or limited, discussion herein of any method of manufacturing or using for a particular device or system, including installing the device or system, should be understood to disclose, as examples of the disclosed technology, the utilized features and implemented capabilities of such device or system.

Thus, for example, some embodiments of the disclosed invention can include prefabricating concrete structures using the couplers as disclosed herein, or securing concrete structures together using the couplers disclosed herein. Similarly, some examples can include manufacturing or using sets of substantially identical couplers (of one or more sizes) for prefabrication or for on-site operations.

It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.

As used herein, unless otherwise limited or defined, “or” indicates a non-exclusive list of components or operations that can be present in any variety of combinations, rather than an exclusive list of components that can be present only as alternatives to each other. For example, a list of “A, B, or C” indicates options of: A; B; C; A and B; A and C; B and C; and A, B, and C. Correspondingly, the term “or” as used herein is intended to indicate exclusive alternatives only when preceded by terms of exclusivity, such as “either,” “one of,” “only one of,” or “exactly one of.” For example, a list of “one of A, B, or C” indicates options of: A, but not B and C; B, but not A and C; and C, but not A and B. A list preceded by “one or more” (and variations thereon) and including “or” to separate listed elements indicates options of one or more of any or all of the listed elements. For example, the phrases “one or more of A, B, or C” and “at least one of A, B, or C” indicate options of: one or more A; one or more B; one or more C; one or more A and one or more B; one or more B and one or more C; one or more A and one or more C; and one or more of A, one or more of B, and one or more of C. Similarly, a list preceded by “a plurality of” (and variations thereon) and including “or” to separate listed elements indicates options of multiple instances of any or all of the listed elements. For example, the phrases “a plurality of A, B, or C” and “two or more of A, B, or C” indicate options of: A and B; B and C; A and C; and A, B, and C.

Also as used herein, unless otherwise limited or defined, “integral” and derivatives thereof (e.g., “integrally”) describe elements that are manufactured as a single piece without fasteners, adhesive, or the like to secure separate components together. For example, an element stamped or cast as a single-piece component from a single piece of sheet metal or a single mold (etc.), without rivets, screws, or adhesive to hold separately formed pieces together, is an integral (and integrally formed) element. In contrast, an element formed from multiple pieces that are separately formed initially, then later connected together, is not an integral (or integrally formed) element.

Also as used herein, unless otherwise limited or specified, “substantially identical” refers to two or more components or systems that are manufactured or used according to the same process and specification, with variation between the components or systems that are within the limitations of acceptable tolerances for the relevant process and specification. For example, two components can be considered to be substantially identical if the components are manufactured according to the same standardized manufacturing operations, with the same materials, and within the same acceptable dimensional tolerances (e.g., as specified for a particular process or product).

Unless otherwise specified or limited, the terms “about” and “approximately,” as used herein with respect to a reference value, refer to variations from the reference value of ±20% or less (e.g., ±15, ±10%, ±5%, etc.), inclusive of the endpoints of the range. Similarly, as used herein with respect to a reference value, the term “substantially equal” (and the like) refers to variations from the reference value of less than ±5% (e.g., ±2%, ±1%, ±0.5%) inclusive. Where specified in particular, “substantially” can indicate a variation in one numerical direction relative to a reference value. For example, the term “substantially less” than a reference value (and the like) indicates a value that is reduced from the reference value by 30% or more (e.g., 35%, 40%, 50%, 65%, 80%), and the term “substantially more” than a reference value (and the like) indicates a value that is increased from the reference value by 30% or more (e.g., 35%, 40%, 50%, 65%, 80%).

Also as used herein, unless otherwise limited or defined, “substantially parallel” indicates a direction that is within ±12 degrees of a reference direction (e.g., within ±6 degrees or ±3 degrees), inclusive. Correspondingly, “substantially vertical” indicates a direction that is substantially parallel to the vertical direction, as defined relative to the reference system (e.g., for a power machine, as defined relative to a horizontal support surface on which the power machine is operationally situated), with a similarly derived meaning for “substantially horizontal” (relative to the horizontal direction). A path that is not linear is substantially parallel to a reference direction if a straight line between end-points of the path is substantially parallel to the reference direction or a mean derivative (i.e., mean local slope) of the path within a common reference frame as the reference direction is substantially parallel to the reference direction.

Also as used herein, unless otherwise limited or defined, “substantially perpendicular” indicates a direction that is within ±12 degrees of perpendicular a reference direction (e.g., within ±6 degrees or ±3 degrees), inclusive. For a path that is not linear, the path can be considered to be substantially perpendicular to a reference direction if a straight line between end-points of the path is substantially perpendicular to the reference direction or a mean derivative (i.e., mean local slope) of the path within a common reference frame as the reference direction is substantially perpendicular to the reference direction.

Unless otherwise specifically indicated, ordinal numbers are used herein for convenience of reference, based generally on the order in which particular components are presented in the relevant part of the disclosure. In this regard, for example, designations such as “first,” “second,” etc., generally indicate only the order in which a thus-labeled component is introduced for discussion and generally do not indicate or require a particular spatial, functional, temporal, or structural primacy or order. Relatedly, similar or identical components may be referred to with different ordinal numbers in different contexts.

The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

	Number	Date	Country
	63623580	Jan 2024	US
	63656314	Jun 2024	US

COUPLER SYSTEM FOR REINFORCED CONCRETE

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CPC

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