Span-to-Span Duct Coupler for Reliable Sealed Joints
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Solution Overview
Problem
Reinforced concrete structures face challenges in efficiently connecting duct segments across adjacent concrete elements, particularly in balanced cantilever constructions, where traditional coupling methods are inadequate for maintaining structural integrity and sealing against fluid ingress.
Innovation Solution
A duct coupler assembly comprising first and second coupler bodies and a coupler boot, which are mechanically coupled to end flanges of duct segments within concrete elements, providing a secure joint and seal to prevent fluid ingress while allowing for tensioning of metal cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coupling methods are used to connect duct segments across adjacent concrete elements, then the device complexity is reduced, but the reliability of the connection and sealing against fluid ingress deteriorates
Solution Approach 1:
The coupler assembly is divided into distinct functional segments: coupler bodies for mechanical connection, boots for sealing, and end flanges for integration with duct segments. This segmentation allows each component to be optimized for its specific function while maintaining overall reliability without excessive complexity.
Solution Approach 2:
The coupler assembly employs composite construction combining rigid coupler bodies (likely metal or reinforced polymer) with flexible sealing boots (elastomeric material). This composite approach provides both structural integrity for mechanical connection and effective sealing against fluid ingress, resolving the contradiction between reliability and complexity.
2Reliability
If a secure joint and seal are provided to prevent fluid ingress, then the reliability improves, but the ease of manufacture deteriorates
Solution Approach 1:
The boots are pre-formed and pre-positioned on the coupler bodies before final assembly with the end flanges. This preliminary action ensures proper sealing geometry is achieved without complex manufacturing steps during final assembly, improving reliability while maintaining ease of manufacture.
Solution Approach 2:
The boot structure is designed to fit over and seal around the interface between coupler bodies and end flanges, creating a nested configuration where the sealing element encompasses the joint. This nesting approach provides effective sealing through a relatively simple manufacturing process.
3Strength
If duct segments are coupled to maintain structural integrity under tensile loading, then the strength improves, but the difficulty of detecting and measuring deteriorates
Solution Approach 1:
The coupler assembly incorporates visual indicators (such as colored seals or marked surfaces) that change or become visible when proper assembly and sealing are achieved. This allows easy detection of joint integrity without complex measurement equipment, resolving the contradiction between strength and detectability.
Data Source
AI summary
A span to span duct coupler includes a coupler, a first end flange, and a second end flange. A first concrete element is formed to include a duct segment and the first end flange. The first end flange may be coupled to the first duct segment by a first duct boot. A second concrete element is formed to include a duct segment and a second end flange. The second end flange may be coupled to the second duct segment by a second duct boot. The coupler may include first and second coupler bodies and a coupler boot coupled to the first and second coupler bodies. The first coupler body may be mechanically coupled to the first end flange. The second coupler body may be coupled to the second end flange.