Multi-Component Resin Mortar Coupling for Rebar Installation
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Solution Overview
Problem
Existing methods for coupling elongated elements, such as reinforcing bars in reinforced concrete, face challenges including limited space, need for heavy equipment, and inefficiencies in threaded, swaged, and grouted coupling devices, which often require tedious on-site modifications and are not suitable for non-pre-cast scenarios.
Innovation Solution
A kit of parts using a coupling device with a multi-component resin mortar system comprising a curable epoxy resin and a curing agent, which allows for easy handling and improved fastening properties, reducing the need for heavy equipment and enhancing mechanical strength, while being compatible with various rebar geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If threaded coupling devices are used to join rebars, then the coupling strength is improved, but heavy equipment is needed to provide the correct torque and the rebars need to be provided with a thread which creates additional challenges
Solution Approach 1:
The patent replaces the threaded mechanical coupling system with a friction-based mechanical press system. Instead of relying on threads and torque application, the invention uses a mechanical press to apply axial compressive force to the rebar ends within the coupling device, creating friction that prevents rotation and enables self-tightening of the coupling mechanism.
Solution Approach 2:
The patent introduces a mechanical press as an intermediary device between the operator and the coupling process. The press applies controlled axial force to the rebar ends, mediating the transfer of force from the coupling device to the rebars, thereby eliminating the need for heavy torque equipment while maintaining coupling strength.
2Ease of operation
If swaged coupling devices are used to achieve coupling without torque, then the ease of operation is improved, but heavy equipment such as hydraulic presses is still needed to apply the forces
Solution Approach 1:
The coupling device is designed to be self-tightening through the application of axial compressive force. As the mechanical press applies force to the rebar ends, the friction generated automatically tightens the coupling mechanism without requiring additional equipment or complex operations, making the system self-servicing during the coupling process.
Solution Approach 2:
The patent replaces the hydraulic press system with a simpler mechanical press system that uses spring-loaded or cam-based mechanisms to apply the necessary axial force. This substitution reduces the weight and complexity of the equipment while maintaining the ability to apply sufficient force for effective coupling.
3Strength
If MBT coupling devices with multiple screws are used, then the coupling strength is improved, but the device complexity and the need for exact torquing with big torque wrenches increases
Solution Approach 1:
The patent extracts the multiple screw fastening mechanism from the coupling device and replaces it with a single axial loading mechanism. By removing the complex multi-screw system and retaining only the essential function of securing the rebar ends through friction and compression, the device complexity is significantly reduced while maintaining coupling strength.
Solution Approach 2:
The patent merges the functions of multiple screws into a single axial loading mechanism. The mechanical press simultaneously applies force to both rebar ends, combining the fastening function that previously required multiple separate screw operations into one unified action, thereby simplifying the device and reducing the number of components.
4Strength
If grouted coupling devices with threaded connections are used for pre-cast parts, then the coupling strength is improved, but the threaded connections stick out of the coupling device thereby limiting the space in the neighborhood
Solution Approach 1:
The patent designs the coupling device with a compact nested structure where all components are contained within the cylindrical housing. The rebar ends, mechanical press elements, and coupling mechanisms are nested within the sleeve, with no protruding threaded connections, thereby minimizing the space required in the neighborhood of the coupling device.
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 solution provides efficient, easy-to-handle coupling with improved mechanical strength and reduced material and labor costs, allowing for shorter coupling device sleeves and higher fire resistance, suitable for both pre-cast and non-pre-cast applications.
Implementation Method 1
the at least one reactive resin in resin component (A) is a curable epoxy resin having an average epoxy functionality of 2 or greater, and the at least one curing agent in hardener component (B) is a curing agent for the curable epoxy resin
Data Source
Figure 1~4
AI summary
Kit of parts for coupling at least two elongated elements comprising two ends with a coupling device, the kit of parts comprising a coupling device, and a multi-component resin mortar system, wherein the coupling device comprises a coupling device body, wherein the coupling device body has an axis, a wall, a hollow body portion having an inner surface, and at least two receiving openings for receiving the at least two elongated elements, wherein the coupling device body comprises at least one support element on the inner surface of the hollow body portion, and wherein the multi-component resin mortar system comprises a resin component (A) comprising at least one reactive resin, and a hardener component (B) comprising at least one hardener for the at least one reactive resin comprised in the resin component (A), wherein the at least one reactive resin in resin component (A) is a curable epoxy resin having an average epoxy functionality of 2 or greater, and the at least one curing agent in hardener component (B) is a curing agent for the curable epoxy resin.