Welded Segmental Duct Coupler Without Internal Seals
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Solution Overview
Problem
Existing duct coupler systems for concrete segments are inefficient and costly due to the need for multiple parts and manual assembly, requiring seals that increase manufacturing and labor costs.
Innovation Solution
A single, discrete annular body made of weldable material with variable diameters that can connect to duct segments without seals, allowing for efficient welding and reduced part complexity, facilitating easier assembly and lower costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional multi-part coupler systems are used, then sealing function is provided, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separate components (coupler body, seals, gaskets) into a single integrated coupler device made from one piece of molded material. The coupler includes integrated features such as recesses for sealing surfaces, protrusions for alignment, and built-in sealing mechanisms, eliminating the need for separate sealing components and reducing assembly steps.
Solution Approach 2:
The single-piece coupler is designed to perform multiple functions simultaneously: providing sealing surfaces through molded recesses, structural connection through integrated geometry, alignment through built-in protrusions, and environmental protection. This multi-functional design replaces what previously required multiple specialized components.
2Reliability
If multiple separate parts are used for coupler assembly, then sealing is achieved, but assembly time and labor cost increase
Solution Approach 1:
By molding the coupler as a single integrated piece with built-in sealing surfaces and alignment features, the patent eliminates the need for separate assembly steps involving multiple components. The coupler is installed as one unit, significantly reducing assembly time and labor requirements while maintaining sealing functionality.
3Strength
If conventional coupler systems with multiple components are used, then connection is achieved, but manufacturing cost increases
Solution Approach 1:
The patent manufactures the coupler as a single molded part, eliminating the need for multiple manufacturing processes and subsequent assembly operations. This single-shot molding process reduces manufacturing complexity, labor costs, and overhead while producing a strong, integrated connection component.
Solution Approach 2:
The coupler utilizes varying wall thicknesses and material distribution within the single-piece structure to optimize strength at critical connection points while minimizing material usage. The molded design allows for complex geometries that provide structural reinforcement where needed without increasing overall complexity.
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 enables more secure, efficient, and cost-effective coupling of duct segments, reducing the need for additional sealing components and simplifying the assembly process, resulting in less expensive and easier-to-install concrete structures.
Implementation Method 1
The body of material can comprise a weldable material that is configured to weld to a duct segment
Data Source
AI summary
Segmental duct coupler devices, systems, and methods are provided herein. A duct coupler device can include a single, discrete body of material for welding to a duct segment. A system, including a duct segment having a duct coupler device welded thereto, is provided. The connection or points of connection between the duct coupler device and the duct segment in the system are devoid of internal and/or external seals. The duct coupler device and system can be cast in concrete. Multiple concrete segments can be assembled together to form a bridge, a roadway, a building, a slab, or any other structure.