Mechanical Coupler for Precast Concrete Rebar Connections
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Solution Overview
Problem
Existing methods for connecting precast concrete modules, such as grout-filled rebar couplers, are time-consuming, require bracing during curing, and are unreliable at low temperatures, while welding methods are costly and difficult to validate for quality.
Innovation Solution
A mechanical coupler system using a cast metal coupler body with threaded connections and reusable locating pins to quickly and securely align and connect axially aligned reinforcing bars in precast concrete panels, eliminating the need for grout and welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If grout-filled rebar couplers are used to connect precast concrete members, then the rebars can be connected, but the connection requires several hours to cure and develop minimum tensile strength
Solution Approach 1:
The patent replaces the chemical grout curing process with a mechanical coupling system. The coupler body with threaded bore and bolt provides immediate mechanical connection between rebars, eliminating the need for chemical curing while maintaining connection strength.
Solution Approach 2:
The coupler body is pre-installed in the lower concrete member during casting, and the threaded bore is prepared in advance. This allows the bolt to be immediately inserted and tightened to provide instant structural connection without waiting for any curing process.
2Reliability
If grout-filled couplers are used, then rebars can be connected, but bracing is required during curing time
Solution Approach 1:
The mechanical bolt connection provides immediate structural stability upon tightening, replacing the temporary stability provided by bracing during grout curing. The direct threaded connection eliminates the need for external support structures.
3Reliability
If grout-filled couplers are used in low ambient temperature, then connection can be achieved, but the wall requires cover and heating
Solution Approach 1:
The mechanical coupling system operates independently of temperature conditions that affect chemical grout curing. The metallic components and threaded connection maintain their mechanical properties across a wide temperature range, providing reliable connection in cold weather without special precautions.
4Reliability
If grout-filled couplers are used, then rebars can be connected, but significant time is required to fill and validate grout strength
Solution Approach 1:
The mechanical bolt connection provides visible and immediate confirmation of proper installation. The threaded connection and bolt tightening provide direct evidence of secure attachment, eliminating the need for delayed strength validation through cube testing.
5Strength
If welding is used to connect precast concrete members, then structural connection can be achieved, but special welding equipment and certified welders are required
Solution Approach 1:
The patent replaces welding with a mechanical threaded connection system. The coupler body with pre-tapped threaded bore and bolt provides equivalent structural strength without requiring welding equipment, certified welders, or complex welding procedures.
6Reliability
If welding is used to connect anchor plates, then precast members can be joined, but quality validation through ongoing tests is required
Solution Approach 1:
The mechanical threaded connection provides inherently verifiable quality through the physical act of螺栓 tightening and threading. The connection strength is immediately apparent through the mechanical engagement, eliminating the need for ongoing welding quality tests and inspections.
Data Source
AI summary
Adjacent precast reinforced concrete modules or members are secured together by a plurality of coupler systems each including a cast metal coupler body embedded in an edge portion of the first concrete member and connected by a coupling member to a reinforcing bar within the first concrete member. The coupler body has an internal cavity with a side opening and an end opening extending to the cavity, and reinforcing wings border the side opening. The second concrete member has another coupling member rigidly connected to an axially aligned reinforcing bar and includes an end portion with a threaded bore. A bolt is inserted into the cavity through the side opening, aligned with the end opening and then threaded into the bore where the bolt is tightened with a wrench extending into the cavity through the side opening. A reusable locating pin may be used to align the concrete members.