Barrier Coupling Element With Self-Aligning Impact-Resistant Locking

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Solution Overview

Problem

Existing barrier elements and connecting elements for concrete barriers are heavy, difficult to produce, and require precise alignment, making them costly and prone to failure under high impact loads and misalignment.

Innovation Solution

A coupling element with inclined abutment surfaces and a cross-section design that allows for easy alignment and strong interconnection, featuring a transversely wide bottom and narrow mouth recess, and hook portions to secure the connection, enabling robust performance under various conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the coupling element uses a complex interlocking mechanism with multiple hooks and legs, then the connection strength between barrier elements is improved, but the ease of manufacture and assembly deteriorates

Engineering Contradiction:

Improveconnection strengthVSAvoidease of manufacture

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The coupling element is divided into distinct functional parts: a body portion and a protrusion portion. This segmentation allows each part to be optimized independently for its specific function while simplifying the overall manufacturing process compared to complex multi-leg hook structures.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention extracts the essential coupling function from complex multi-hook mechanisms and concentrates it into a single protrusion structure with inclined abutment surfaces. This extraction maintains connection strength while dramatically simplifying the manufacturing and assembly process.

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If the coupling element uses a complex interlocking mechanism with multiple hooks and legs, then the connection strength between barrier elements is improved, but the ease of interconnection deteriorates

Engineering Contradiction:

Improveconnection strengthVSAvoidease of interconnection

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

Instead of using multiple hooks that need to be manually aligned and engaged, the invention inverts the approach by using a protrusion that passively engages with a corresponding recess through vertical movement. The inclined abutment surfaces automatically guide the engagement process, making interconnection easier while maintaining strength.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The coupling mechanism is designed to self-align and self-lock through the inclined abutment surfaces. When barrier elements are moved vertically relative to each other, the protrusion automatically engages with the recess and the inclined surfaces create frictional engagement that secures the connection without requiring manual adjustment or complex alignment procedures.

Inventive Principle:

Principle #25Self-service

3Strength

If the coupling element uses tight tolerances to ensure strong connection, then the connection strength is improved, but the manufacturing cost increases

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention changes the geometric parameters of the coupling surfaces by using inclined abutment surfaces instead of flat or curved surfaces. This parameter change allows for wider tolerances while maintaining strong connection through the mechanical advantage provided by the inclined geometry and frictional engagement.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The protrusion and recess are designed with asymmetric inclined abutment surfaces that provide strong engagement in the intended direction while allowing for tolerance variations. The asymmetric geometry ensures proper load transfer without requiring tight manufacturing tolerances.

Inventive Principle:

Principle #4Asymmetry

4Adaptability or versatility

If the coupling element is designed to be insensitive to shape deviations, then the robustness against misalignment is improved, but the connection strength may deteriorate

Engineering Contradiction:

Improverobustness against misalignmentVSAvoidconnection strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The coupling mechanism incorporates dynamic elements through the inclined abutment surfaces that allow for adjustment and adaptation during engagement. The inclined surfaces can accommodate misalignment by self-adjusting through frictional contact, maintaining both robustness against misalignment and connection strength simultaneously.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP4530403B1Coupling element, barrier element, and barrier

Publication Date: 2026.04.29 GUNNAR PREFAB

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AI summary

The disclosure relates to a coupling element (10) comprising a coupling portion (30) having a cross-section which comprises a first longitudinal protrusion (40) and a second longitudinal protrusion (50) between them forming an open recess (60) which has a transversely wide bottom portion (61) and a transversely narrow mouth portion (62) and which is configured to receive, by a relative vertical movement between the first and second barrier elements (1, 2), a first protrusion (240) of the corresponding coupling element (210) of the second barrier element (2), wherein the first protrusion (40) has a first portion (41) and a second portion (42) arranged one after the other along the longitudinal direction (L), wherein the first portion (41) has on an inner side a first inclined abutment surface (41a) and the second portion (42) has on an inner side a second inclined abutment surface (42a). Also disclosed is a barrier element (1, 2) and a barrier (300).