Grout to Grout Rebar Coupler with Segmented Internal Ribs
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Solution Overview
Problem
Existing rebar connectors for reinforced concrete structures face challenges in efficient grouting, off-gassing issues, and limited flexibility in prefabrication and installation, leading to reduced coupling strength and increased grout usage.
Innovation Solution
The development of a rebar connector with a coupler body featuring a hollow interior, grout ports, set screws, and internal ribs to align and secure rebars, along with a removable cap and stop assembly for improved grout distribution and reduced grout volume, enhancing prefabrication and on-site assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional rebar connectors are used, then coupling strength is achieved, but grout usage is excessive and off-gassing issues occur
Solution Approach 1:
The hollow interior is divided into multiple cells by internal ribs, creating separate compartments for grout injection. This segmentation allows controlled grout distribution and reduces total grout volume needed while maintaining coupling strength through localized grout placement in critical areas.
Solution Approach 2:
Grout is selectively placed in specific cells rather than filling the entire hollow interior uniformly. The internal ribs create zones with different grout volumes, concentrating grout where it provides maximum bonding benefit while reducing overall grout consumption and minimizing off-gassing from excess grout.
2Adaptability or versatility
If conventional coupler designs are used, then rebar connection is achieved, but flexibility in prefabrication and installation is limited
Solution Approach 1:
Rebars are positioned and secured within the coupler body before grout injection using set screws and internal ribs. This preliminary positioning ensures correct alignment and spacing, allowing efficient on-site assembly and reducing installation time while maintaining connection reliability.
Solution Approach 2:
The coupler design allows for adjustable rebar positioning through removable set screws and flexible internal rib configurations. This dynamic adjustment capability provides versatility for different rebar sizes and installation scenarios while maintaining ease of grouting through the designated grout ports.
3Reliability
If grout is injected into traditional connectors, then rebar bonding is achieved, but off-gassing effects reduce connection quality
Solution Approach 1:
The internal ribs divide the grout injection space into separate cells, allowing controlled air escape paths and preventing trapped air pockets that cause off-gassing issues. Each cell can be independently filled, reducing pressure buildup and harmful gas formation during grout curing.
Solution Approach 2:
The design extracts and removes air pockets and excess grout through strategically positioned grout ports and cell configurations, preventing off-gassing from compromising the connection quality. The segmented structure allows air to escape during grout injection rather than being trapped.
Data Source
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AI summary
A rebar coupler (120) can have a coupler body (140) with a hollow interior, and a first end (150) and a second end (154) that are open to the hollow interior to receive rebar into opposing ends of the hollow interior along a longitudinal axis (LA). One or more grout ports can be included on the coupler body (140), including a first grout port (160) on the first end (150) of the coupler body (140). The coupler body (140) can include a set screw (142), a removable stop, a narrowed first end, a removable cap, or other features.