Single-Piece Sleeve Coupler for Parallel Rebar Splicing
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Solution Overview
Problem
Existing reinforcing bar couplers are cumbersome, require specialized tools, and involve complex manufacturing steps, making them difficult to use and costly for securing reinforcing bars in concrete structures.
Innovation Solution
A single-piece, sleeve-based coupler with angled sidewalls and grip protrusions that securely holds parallel reinforcing bars in place using a continuous thermoplastic material, reducing the need for additional fasteners and manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If prior coupler designs use pins and fasteners to wedge between reinforcing bars, then the coupler can secure the bars, but it requires specialized tools and careful manipulation, increasing device complexity and difficulty of operation
Solution Approach 1:
The patent merges the function of multiple separate fastening components (pins, fasteners, wedges) into a single integrated sleeve structure. The sleeve includes integrated features such as ridges, grooves, and tapered sections that collectively perform the securing function, eliminating the need for separate pins and fasteners. This reduces device complexity while maintaining the reliability of securing reinforcing bars.
Solution Approach 2:
The sleeve is divided into functional zones: tapered end portions for insertion, a body portion with ridges and grooves for securing, and grip portions for handling. This segmentation allows each zone to perform its specific function efficiently, simplifying the overall operation and reducing the need for specialized tools.
2Reliability
If prior coupler designs involve manipulation of the coupler or reinforcing bars within the coupler, then the bars can be secured, but it becomes difficult and unwieldy due to the weight of the reinforcing bars and the location of the splice
Solution Approach 1:
The reinforcing bars are pre-positioned in parallel alignment before insertion into the sleeve. The tapered end portions of the sleeve are designed to guide the bars into place, performing the alignment action preliminarily and reducing the need for difficult manipulation during installation, especially in hard-to-reach locations.
Solution Approach 2:
The tapered geometry of the sleeve end portions enables the bars to be inserted and secured through simple insertion motions without requiring complex manipulation. The structure itself facilitates the installation process, making it easier to operate even when dealing with heavy bars or elevated splice locations.
3Reliability
If prior coupler designs use additional fasteners and intervening structures, then the bars can be coupled, but it involves additional manufacturing steps, increasing the cost of the coupler
Solution Approach 1:
The patent combines multiple fastening functions into a single monolithic sleeve structure that can be manufactured in one piece using processes like injection molding. This eliminates the need to manufacture and assemble separate pins, fasteners, and wedges, significantly simplifying the manufacturing process while maintaining coupling strength through integrated structural features.
Data Source
AI summary
A single-piece construction coupler for securing reinforcing bars in a parallel relationship includes a sleeve having a center portion, a first end portion extending from one end of the center portion, a second end portion extending from the opposing end of the center portion, and a channel. The center portion includes opposing sidewalls connected by an upper wall, and each of the end portions comprise opposing sidewalls connected by lower walls. Securing tabs extend into the channel from the bottom of the upper wall. Ridges extend into the channel from each of the lower walls and the upper wall. The center portion and the end portions each include fillets connecting the sidewalls and the ridges to upper and lower walls to form rounded surfaces for receiving the reinforcing bars. The sleeve also includes grip protrusions on its outer surfaces.