Self-Gripping Rebar Coupler With Opposing-Force Wedge Locking

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Solution Overview

Problem

Existing rebar coupling methods require excessive manual labor, heavy equipment, and pose safety risks, particularly in demanding construction situations, with issues such as slippage, non-compliance with stringent standards, and increased risk of accidents.

Innovation Solution

A rebar coupler with a two or three primary body configuration, featuring male and female threaded housings, internal components like an internal cylinder, tightening members, and springs, that creates opposing forces to securely grip rebar, minimizing slip and meeting regulatory standards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional rebar coupling methods (welding, mechanical jointing, twisting) are used, then rebar can be connected, but excessive manual labor and heavy equipment are required, posing safety risks to workers

Engineering Contradiction:

Improveconnection reliabilityVSAvoidease of coupling operation

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The rebar coupler is designed to be self-gripping, where the tightening members automatically engage and secure the rebar ends when the coupler bodies are assembled together, eliminating the need for external twisting tools or heavy equipment while ensuring reliable connection

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The coupler is divided into multiple functional components including first and second coupler bodies, tightening members, and bearing surfaces, allowing each component to perform its specific function independently while working together to achieve secure rebar connection without requiring excessive manual labor

Inventive Principle:

Principle #1Segmentation

2Reliability

If twisting of rebar is required for threaded coupling, then rebar can be joined, but high energy expenditure and increased injury risk are incurred by workers

Engineering Contradiction:

Improvecoupling strengthVSAvoidenergy expenditure by worker

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The invention replaces the traditional mechanical twisting system with a threaded coupling system where pre-formed threads on the rebar ends engage with corresponding threads in the coupler bodies, converting the high-energy twisting action into a low-energy screwing motion that requires minimal worker energy expenditure while maintaining coupling strength

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If multiple bolts are used to clamp rebar ends, then secure connection is achieved, but excessive effort and cumbersome tools are required

Engineering Contradiction:

Improveconnection securityVSAvoidcoupling mechanism complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention merges the functions of multiple bolts and clamping mechanisms into a single integrated coupler body structure where the first and second coupler bodies themselves act as the clamping elements, eliminating the need for separate bolts and reducing the overall device complexity while maintaining connection security

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If heavy equipment is used for rebar coupling, then coupling can be performed, but safety risks and potential accidents are increased

Engineering Contradiction:

Improvecoupling efficiencyVSAvoidsafety risks to workers

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The self-gripping mechanism automatically secures the rebar ends when the coupler is assembled, eliminating the need for heavy external equipment and thereby removing the associated safety risks while maintaining efficient coupling operation

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Instead of using heavy equipment to force the coupling, the design inverts the approach by having the coupler itself generate the gripping force through its internal tightening members and bearing surfaces, achieving secure connection without external heavy equipment and thus improving worker safety

Inventive Principle:

Principle #13The other way round (Inversion)

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 rebar coupler simplifies the installation process, reduces manual labor and equipment needs, enhances structural integrity, and meets stringent regulatory requirements, minimizing slip and safety risks, particularly in cyclical loading conditions.

Implementation Method 1

at least one spring extending through the internal cylinder

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The tightening members can comprise a set of wedges with tapered bearing surfaces

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12392135B2Self-gripping, no-slip rebar coupler

Publication Date: 2025.08.19 KHAN IMRAN N

AI summary

The invention comprises an improved rebar coupler designed to simplify joining rebar while minimizing slippage. It features a male and female threaded external housing, an internal cylinder, springs, and tightening members with wedges. The coupler creates an opposing force to lock rebar securely, addressing challenges in existing methods. Available in two-piece and three-piece configurations, it accommodates various rebar sizes without modification. The design allows for single-person operation, reduces manual labor, and enhances structural integrity. The rebar coupler meets stringent standards like CalTrans CT670, offering advantages over existing products by eliminating heavy equipment needs and complex installation procedures.