Flexible Tail Protective Cap for Coupler Bar Exposure
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Solution Overview
Problem
The process of locating and exposing couplings in steel-reinforced concrete structures is labor-intensive and time-consuming due to the need for manual removal of protective covers and concrete clearing, which increases project costs and duration.
Innovation Solution
A protective cap with a flexible tail is used to cover and protect coupler bars, allowing easy exposure by pulling the tail after concrete setting, reducing manual labor and time required for coupling preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional protective covers are used on couplings, then damage to the coupling is prevented, but removal of the protective covers increases the time needed to expose the coupling
Solution Approach 1:
The protective cap is divided into two functional segments: a rigid body portion that protects the coupling and a flexible tail that serves as a removal mechanism. This segmentation allows the protective function to be maintained while enabling rapid removal by simply pulling the tail, eliminating the need for tools or manual disassembly of the cap itself.
Solution Approach 2:
The flexible tail acts as an intermediary element between the user and the protective cap body. By attaching the tail to the cap body, it provides a convenient grip point for removal without requiring direct manipulation of the cap itself, thus simplifying the removal process and reducing time loss.
2Ease of operation
If manual clearing of concrete from couplings is performed, then the coupling is exposed for connection, but the process is highly labor intensive
Solution Approach 1:
The protective cap is installed on the coupling before the concrete pouring operation. This preliminary action ensures the coupling is protected during concrete placement, and the cap's design with an extending tail facilitates easy removal and concrete clearance afterward, significantly reducing the labor intensity of the exposure process.
Solution Approach 2:
The flexible tail extending from the protective cap allows workers to easily grip and remove the cap without requiring specialized tools or complex procedures. This self-service design enables rapid removal and facilitates quicker concrete clearance, thereby improving overall productivity in the coupling exposure process.
3Reliability
If protective covers are removed only after concrete clearing, then the coupling is protected during pouring, but the overall process time increases
Solution Approach 1:
By segmenting the protective cap into a body and a flexible tail, the design enables the cap to remain protective during concrete pouring while allowing for rapid removal afterward. The tail segment specifically serves as a removal handle, enabling workers to quickly extract the cap once pouring is complete, thus shortening the total process duration without compromising protection during the critical pouring phase.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The protective cap efficiently protects couplings from damage and facilitates quick exposure by displacing concrete, thereby reducing labor and time needed for coupling preparation in concrete structures.
Implementation Method 1
a flexible tail (110) having a first end and a second end, wherein the first end is attached to the back portion of the body
Data Source
AI summary
The present invention generally relates to methods and apparatus for protecting a coupling that is disposable within a concrete structure. In one aspect, a cap for engaging a coupling of a cement coupler bar is provided. The cap includes a body having an engagement portion and a back portion, wherein the engagement portion is configured to engage the coupling of the cement coupler bar. Additionally, the cap includes a flexible tail having a first end and a second end, wherein the first end is attached to the back portion of the body. In another aspect, a method of using a protective cap with a coupling of a cement coupler bar is provided. In a further aspect, a coupler bar assembly for use in reinforcing a cement structure is provided.