Abstract:
Embodiments of the present invention generally relate to a method and an apparatus for connecting adjacent concrete structures. In one aspect, a coupling assembly for connecting adjacent concrete structures erected for street, roadway or highway use is provided. The coupling assembly includes a first anchor device with a female end comprising a socket having at least one slot. The coupling assembly further includes a second anchor device with a male end comprising at least one projection configured to mate with the at least one slot in the socket, wherein the second anchor device is movable from a first position to a second position in order to couple the male end to the female end. In another aspect, a method of coupling a first anchor device to a second anchor device is provided.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The invention generally relates to a method and an apparatus for connecting adjacent concrete structures used for roadways, streets and highways. More specifically, embodiments of the present invention relate to a method and an apparatus for attaching devices embedded in the adjacent concrete structures for the purpose of securely joining the concrete structures together into a unified road or highway with sufficient strength to prevent the structures from separating due to traffic and natural environmental conditions. 
         [0003]    2. Description of the Related Art 
         [0004]    Concrete streets, roads and highways are typically constructed in parallel concrete structures. These structures must be joined together to form the completed roadway. The conventional method for coupling the adjacent concrete structures into a single road or highway employs the use of a length of common reinforcing steel bars with a threaded coupling device attached to the end. These are used in pairs, with one bar having a female coupler, and the other bar a male coupler. Prior to placement of concrete to form the first structure, one of the bars is fixed at a location and height within the designed area of concrete placement, so that the bar portion is completely encased within the concrete. Immediately after the placement of the concrete, and prior to full hardening of the concrete, the coupler portion of the bar is located within the concrete, and the concrete around the coupler portion is removed in order to allow access to the coupler portion. 
         [0005]    Prior to placement of the• concrete for the next adjacent concrete structure, the second portion of the coupler is attached by the threaded coupler device to the first bar embedded in the first concrete structure. Together these two bars, joined• by a threaded coupler, form a single bar that serves to prevent the two structures from separating in response to the natural forces of traffic and changing environmental conditions. 
         [0006]    Prior to placement of concrete for the second structure, the workers remove the thread protectors from the bar portion embedded in the first concrete structure, and then manually thread the second bar into the threads of the first bar. Typically, the threading process involves simply starting the threading, and power tools, such as heavy duty drills, are used to complete the threading. This method of attaching the coupling bars presents several significant difficulties for assuring completion of the coupling joint. For example, there is no sure means by visual inspection to insure that all bars were finally seated after the initial threading start. A bar that may have been inadvertently skipped when using the power tool to firmly screw down the joints will appear no different from those that were properly completed. In another example, the initial threading start could have been cross threaded, which will then result in stripping of the threads during the power screw down. In either event, the strength of the coupling joint is lost, and there is no means of identifying this deficiency from a visual inspection. In a further example, the thread quality can be compromised by concrete and debris entering the connection and/or by rust. 
         [0007]    Thus, the embodiments of the present invention are directed to a method and an apparatus that seek to overcome these difficulties and other limitations known in the art. 
       SUMMARY OF THE INVENTION 
       [0008]    Embodiments of the present invention generally relate to a method and an apparatus for connecting adjacent concrete structures. In one aspect, a coupling assembly for connecting adjacent concrete structures erected for street, roadway or highway use is provided. The coupling assembly includes a first anchor device with a female end comprising a socket having at least one slot. The coupling assembly further includes a second anchor device with a male end comprising at least one projection configured to mate with the at least one slot in the socket, wherein the second anchor device is movable from a first position to a second position in order to couple the male end to the female end. 
         [0009]    In another aspect, a method of coupling a first anchor device to a second anchor device is provided. The method includes the step of inserting a male end of the second anchor device into a female end of the first anchor device. The method also includes the step of aligning a projection on the male end with a slot in the female end. Additionally, the method includes the step of moving the second anchor device from a first position to a second position, thereby causing the projection to mate with the slot. 
         [0010]    In yet a further aspect, a coupling assembly for connecting adjacent concrete structures erected for street, roadway or highway use is provided. The coupling assembly includes a first anchor device having a female end comprising a socket with a first opening and a second opening. The coupling assembly further includes a second anchor device having a male end comprising at least one projection, wherein the male end of the second anchor device is configured to be inserted into the second opening of the socket and then rotated relative to the socket such that a portion of the male end engages the first opening. 
         [0011]    Additionally, a method of coupling a first anchor device to a second anchor device is provided. The method includes the step of inserting a male end of the second anchor device into a second opening of a female end of the first anchor device. The method further includes the step of aligning a projection on the male end with a shaped portion in the female end. Additionally, the method includes the step of rotating the second anchor device relative to the first concrete bar such that a portion of the male end engages a first opening of the female end. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments. 
           [0013]      FIG. 1  illustrates a quick connect coupling assembly in accordance with an embodiment of the invention. 
           [0014]      FIG. 2  illustrates a cross-sectional view of a female end in the quick connect coupling assembly. 
           [0015]      FIG. 3  illustrates a cross-sectional view of a male end in the quick connect coupling assembly. 
           [0016]      FIG. 4  illustrates the quick connect coupling assembly. 
           [0017]      FIG. 5  illustrates a cross-sectional view of the quick connect coupling assembly prior to rotation of the male end. 
           [0018]      FIG. 6  illustrates a cross-sectional view of the quick connect coupling assembly after the rotation of the male end. 
           [0019]      FIG. 7  illustrates a side view of a quick connect coupling assembly in accordance with a further embodiment of the invention. 
           [0020]      FIG. 8  illustrates a top view of the quick connect coupling assembly. 
           [0021]      FIGS. 9-12  illustrate the connection of the quick connect coupling assembly. 
           [0022]      FIGS. 13-15  illustrate the connection of a quick connect coupling assembly in accordance with a further embodiment of the invention. 
           [0023]      FIGS. 16-20  illustrate the connection of a quick connect coupling assembly in accordance with a further embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals, respectively. The drawing figures are not necessarily to scale. Certain features of the invention may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in the interest of clarity and conciseness. 
         [0025]      FIG. 1  is a view of a quick connect coupling assembly  100  in accordance with an embodiment of the invention. The quick connect coupling assembly  100  is configured to connect adjacent concrete structures. The concrete structures may be used in roadways, streets and highways. The coupling assembly  100  includes a first anchor device  110  with a female end  105  and a second anchor device  120  with a male end  115 . Generally, the first anchor device  110  includes a portion that will be attached or embedded in one concrete structure (not shown), and the second anchor device  120  includes a portion that will be attached or embedded in another adjacent concrete structure (not shown). As illustrated, the second anchor device  120  is longitudinally aligned to the first anchor device  110 . The male end  115  is attached to the second anchor device  120  and is configured to be inserted into the female end  105 . The female end  105  is attached to the first anchor device  110  and comprises a socket  140 . The socket  140  is configured to mate with the male end  115 . For instance if the male end  115  has a tapered end, then the socket  140  of the female end  105  will be configured to mate with the tapered end of the male end  115 . The socket  140  may have any suitable inner diameter. However, the socket  140  preferably has an inner diameter substantially the same as an outer diameter of the male end  115 . 
         [0026]    In certain embodiments, the male end  115  and the female end  105  are coupled using a bayonet mechanism or a bayonet-type coupling which will be described in more detail herein. Generally, a “bayonet mechanism” or a “bayonet coupling” means any connection involving a male end having at least one projection in which the male end engages with a female end which has corresponding slots that mate with the at least one projection. A bayonet mechanism usually involves inserting the male end into the female end and then rotating the male end no more than about 180° about a longitudinal axis of the coupling assembly in order to lock or secure the connection between the male end and the female end. It is generally designed for rapid coupling and decoupling, involving the turning of one part through only a small arc, as compared to a screw-type arrangement, which requires several full turns. 
         [0027]    Generally, the male end  115  is inserted into the female end  105  in a first position. The male end  115  is then moved to a second position to fully engage female end  105 . As such, securing the coupling assembly  100  typically entails the movement of the second anchor device  120  in a direction away from the first anchor device  110 . Moreover, the second anchor device  120  is usually axially rotated in order to fully engage the male end  115  and the female end  105 . As defined herein, “axially rotating” or “axial rotation” means rotating an element about its longitudinal axis. The degree of axial rotation required to secure the coupling assembly  100  varies depending on the locking mechanism (i.e. bayonet mechanism), incorporated into the male end  115  and the female end  105 . The degree of rotation is no more than about 360°, typically no more than about 180°. In other embodiments, the second anchor device does not need to be axially rotated in order to fully engage the male end and the female end. It should be noted that the anchor devices  110 ,  120  in the coupling assembly  100  are connected without the use of threads or a threaded portion. 
         [0028]    As illustrated in  FIGS. 1 and 2 , the socket  140  of the first anchor device  110  includes a plurality of slots  150  (or grooves) that correspond to a plurality of projections  125  on the male end  115 . In one embodiment, at least one of the slots  150  has a longitudinal axis that is parallel to a longitudinal axis of the first anchor device  110 . Between each pair of slots  150  is a lug that corresponds to the space between each pair of projections  125  on the male end  115 . The socket  140  also includes a plurality of the recesses  160 . The recesses  160  define a second set of recesses  165 . A portion of each recess  165  is aligned with each slot  150  allowing the male end  115  to be inserted from a front portion to a back portion of the socket  140 . Furthermore, each recess  165  has a width which is wider than the width of each slot  150 . In addition, each recess  165  includes an arcuate surface  170  which allows the male end  115  to rotate in the socket  140  a predefined amount of degrees. 
         [0029]    The male end  115  and the corresponding female end  105  comprise a bayonet mechanism capable of forming a locked connection by axially rotating the second anchor device  120  no more than about 180°. As shown in  FIGS. 1 and 3 , the male end  115  includes the projection  125 . It should noted that the male end  115  may include any number of projections  125  without departing from principles of the present invention. In the embodiment illustrated in  FIGS. 2-6 , the male end  115  includes four projections  125 . Generally, the projections  125  are evenly spaced around the perimeter of the male end  115 . However, the projections may be in any configuration around the perimeter of the male end  115 . Additionally, the projections  125  may be any type of projections known in the art, such as lugs, teeth, shoulders, tabs, pins, etc. 
         [0030]    As shown in  FIG. 1 , the second anchor device  120  may optionally include an arm  130 . Generally, the arm  130  allows a user to visually confirm that the second anchor device  120  is securely connected to the first anchor device  110  when the second anchor device  120  is rotated about its longitudinal axis upon locking the coupling assembly  100 . Thus, as a user individually inspects each anchor device connection, the user can easily determine visually whether a secure connection has been made by examining the orientation of the arm  130 . In one embodiment, the arm  130  may be a portion of the second anchor device  120  that has been bent at an angle. In another embodiment, the arm  130  may be a separate bar (not shown) that is coupled to the second anchor device  120 . The arm  130  is typically perpendicular to the second anchor device  120 . However, the arm  130  may be at any angle in relation to the second anchor device  120  without departing from principles of the present invention. 
         [0031]    As set forth in  FIG. 4 , the male end  115  is axially aligned with the female end  105  such that the projections  125  are aligned with the slots  150 . The male end  115  is then inserted through a socket opening  145  of the socket  140 . As a user pushes the male end  115  through the socket  140 , the male end  115  slides into the female end  105  until the tip of the male end  115  contacts an inner surface  135 , signaling that the male end  115  is fully inserted into the socket  140 . At this point, the user may rotate the second anchor device  120  using the arm  130  to secure the coupling assembly  100 . 
         [0032]    As illustrated in  FIGS. 5 and 6 , when the male end  115  is rotated about its longitudinal axis to a predetermined degree (i.e. 90°), the plurality of projections  125  contact the plurality of abutments  160  preventing further rotation. Moreover, in some embodiments, after the second anchor device  120  is rotated, the second anchor device  120  is pulled in a direction away from the first anchor device  110  such that the projections  125  slide into longitudinal recesses located in the female end  105  to further secure or lock the connection assembly  100 . Thus, the first anchor device  110  is securely coupled with the second anchor device  120  when the second anchor device  120  is rotated about its longitudinal axis no more than about 180°. 
         [0033]      FIG. 7  is a side view and  FIG. 8  is a top view of a quick connect coupling assembly  200  in accordance with a further embodiment of the invention. The quick connect coupling assembly  200  is configured to connect adjacent concrete structures. The concrete structures may be used in roadways, streets and highways. The coupling assembly  200  includes a first anchor device  210  with a female end  205  and a second anchor device  220  with a male end  215 . Generally, the first anchor device  210  includes a portion that will be attached or embedded in one concrete structure (not shown), and the second anchor device  220  includes a portion that will be attached or embedded in another adjacent concrete structure (not shown). The male end  215  is configured to be inserted into the female end  205 . The male end  215  includes at least one lateral projection  225 , more preferably at least two projections  225 . Each lateral projection  225  may include a shoulder  270 . As shown in  FIG. 8 , the shoulders  270  are angled toward the back of the male end  215 . However, it should be noted that the shoulders  270  may be angled in any suitable direction without departing from principles of the present invention. The male end  215  further includes an optional protective flange  280  (or the guard) to prevent dirt or residue from entering the coupling assembly  200 . 
         [0034]    The female end  205  includes a socket  250  that is adapted to fit the lateral projections  225  of the male end  215 . As shown, the socket  250  includes an axial socket opening  245  located longitudinally along an outer surface of the female end  205 . A first portion  235  of the socket  250  includes a plurality of longitudinal recesses  260  adapted to fit the lateral projections  225  of the male end  215 . The recesses  260  are configured with bevels  265  that mate with the shoulders  270  of the lateral projections  225  in order to lock the male end  215  in the female end  205 . 
         [0035]      FIGS. 9-12  illustrate sequential steps in the connection of the quick connect coupling assembly  200 . Generally, the male end  215  is inserted into the female end  205  in a first position and then moved to a second position to fully engage female end  205 . As illustrated in  FIG. 9 , the male end  215  is inserted through the opening  245  into the socket  250  in a radial direction. In one embodiment, the socket opening  245  is configured such that the male end  215  may only be inserted with the lateral projections  225  substantially perpendicular to the opening  245 . Moreover, the lateral projections  225  are only fully insertable at an end portion of the socket  250 . As illustrated in  FIG. 10 , after the male end  215  is fully inserted into the socket  250  (i.e. the first position), the second anchor device  220  is rotated relative to the first anchor device  210  about its longitudinal axis (about 90 degrees). The second anchor device  220  may optionally include an arm  230  that allows a user to visually confirm that the second anchor device  220  is securely connected to the first anchor device  210 . Thus, as the user individually inspects each rebar connection, the user can easily determine visually whether a secure connection has been made by examining the orientation of the arm  230 . It should be noted that the anchor devices  210 ,  220  in the coupling assembly  200  are connected without the use of threads or a threaded portion. 
         [0036]    As illustrated in  FIGS. 11 and 12 , after the second anchor device  220  is rotated, the second anchor device  220  is pulled in a direction away from the first anchor device  210 . The axial movement of the second anchor device  220  relative to the first anchor device  210  causes the lateral projections  225  on the male end  215  to slide from a back portion  240  of the socket  250  to a front portion  235  and into the recesses  260  (i.e. the second position). At this point, the shoulders  270  of the lateral projections  225  on the male end  215  engage with the bevels  265  in the female end  205 , thereby releasably locking the male end  215  to the female end  205  in the coupling assembly  200 . 
         [0037]      FIGS. 13-15  illustrate sequential steps in the connection of the quick connect coupling assembly  300  in accordance with a further embodiment of the invention. The quick connect coupling assembly  300  is configured to connect adjacent concrete structures. The concrete structures may be used in roadways, streets and highways. The coupling assembly  300  includes a first anchor device  310  with a female end  305  and a second anchor device  320  with a male end  315 . Generally, the first anchor device  310  includes a portion that will be attached or embedded in one concrete structure (not shown), and the second anchor device  320  includes a portion that will be attached or embedded in another adjacent concrete structure (not shown). The male end  315  is configured to be inserted into the female end  305 . The male end  315  includes a bottom lateral projection  325  with an angled shoulder  375  and two side lateral projections  380  with flat shoulders  370 . In alternative embodiments, the side lateral projections  380  may also have angled shoulders (not shown) and the bottom lateral projection  325  may have a flat shoulder (not shown). The male end  315  may further include an optional protective flange  330  (or the guard) to prevent dirt or residue from entering the coupling assembly  300 . 
         [0038]    The female end  305  includes a socket  350  that is adapted to fit the lateral projections  325 ,  380  of the male end  315 . As shown, the socket  350  includes an axial socket opening  345  located longitudinally along an outer surface of the female end  305 . The socket  350  is configured such that the male end  315  may be inserted at an angle with respect to the socket opening  345 . A front portion of the socket  350  includes a bevel  365  and a longitudinal recess  385  to engage the lateral projections  380 ,  325  of the male end  315 . 
         [0039]    As illustrated in  FIG. 13 , the male end  315  is inserted at an angle relative to the female end  305  through the socket opening  345  into the socket  350 . The lateral projections  380 ,  325  are fully insertable only at a back portion  340  of the socket  350 . As illustrated in  FIG. 14 , once the male end  315  is fully inserted, the second anchor device  320  is rotated about an axis substantially perpendicular to its longitudinal axis no more than 180°. As illustrated in  FIG. 15 , the second anchor device  320  is locked to secure the male end  315  in the female end  305  and form the coupling assembly  300 . At this point, the angled shoulder  375  of bottom lateral projection  325  engages with the bevel  365  while at substantially the same time, the shoulders  370  of the side lateral projections  380  engage with the longitudinal recesses  385  to lock the coupling assembly  300 . In one embodiment, the second anchor device  320  is moved relative to the first anchor device  310  to secure the male end  315  in the female end  305  and form the coupling assembly  300 . It should be noted that the anchor devices  310 ,  320  in the coupling assembly  300  are connected without the use of threads or a threaded portion. 
         [0040]      FIGS. 16-20  are views of a quick connect coupling assembly  400  in accordance with a further embodiment of the invention. The quick connect coupling assembly  400  is configured to connect adjacent concrete structures. The concrete structures may be used in roadways, streets and highways. The coupling assembly  400  includes a first anchor device  410  with a female end  405  and a second anchor device  420  with a male end  415 . Generally, the first anchor device  410  includes a portion that will be attached or embedded in one concrete structure (not shown), and the second anchor device  420  includes a portion that will be attached or embedded in another adjacent concrete structure (not shown). The male end  415  is attached to the second anchor device  420  and the male end  415  is configured to be inserted into the female end  405 . The female end  405  is attached to the first anchor device  410 . The female end  405  includes a socket  440  that is configured to mate with the male end  415 . For instance if the male end  415  has a tapered end, then the socket  440  of the female end  405  will be configured to mate with the tapered end of the male end  415 . The socket  440  may have any suitable inner diameter. However, the socket  440  preferably has an inner diameter substantially the same as an outer diameter of the male end  415 . 
         [0041]    As illustrated in  FIG. 16 , the socket  440  of the first anchor device  410  includes at least one of slot  450  (or groove) that corresponds to projections  425  on the male end  415 . In one embodiment, the slot  450  has a longitudinal axis that is perpendicular to a longitudinal axis of the first anchor device  410 . It should noted that the male end  415  may include any number of projections  425  without departing from principles of the present invention. In the embodiment illustrated in  FIG. 16 , the male end  415  includes two projections  425 . Generally, the projections  425  are spaced around the perimeter of the male end  415 . However, the projections may be in any configuration around the perimeter of the male end  415 . Additionally, the projections  425  may be any type of projections known in the art, such as lugs, teeth, shoulders, tabs, pins, etc. 
         [0042]    As shown in  FIG. 17 , the male end  415  is inserted into the female end  405  at an angle, such as 45°. More specifically, the male end  415  is inserted through a socket opening  445  (i.e. top opening) of the socket  440 . As a user pushes the male end  415  into the socket  440 , the male end  415  slides into the female end  405  until the tip of the male end  415  contacts an inner surface  435 , signaling that the male end  415  is fully inserted into the socket  440 . At this point, the male end  415  is rotated relative to the female end  405  to engage the female end  405  as shown in  FIGS. 17 and 18  such that a portion of the male end  415  engages a front opening of the socket  440 . As illustrated, the first anchor device  410  is attached to the socket  440  on a side opposite the front opening. It should be noted that securing the coupling assembly  400  typically entails the movement of the second anchor device  420  relative to the first anchor device  410 . 
         [0043]    As set forth in  FIG. 18 , the male end  415  is axially aligned with the female end  405  such that the projections  425  are engaged with the slot  450 .  FIG. 19  is a top view of the coupling assembly  400 .  FIG. 20  is a sectional view taken along lines  20 - 20  of  FIG. 19 . As shown in  FIG. 20 , the male end  415  of the second anchor device  420  is fully engaged with the female end  405  of the first anchor device  410 . It should be noted that the anchor devices  410 ,  420  in the coupling assembly  400  are connected without the use of threads or a threaded portion. 
         [0044]    In reference to  FIGS. 1-20 , the female end and the male end of the first and the second anchor devices are typically manufactured by casting or cold-forming. However, any suitable manufacturing methods may be used to fabricate the male and female ends. In one embodiment, the coupling assembly formed between the female end and the male end is at least 1.2 times to about 2 times stronger than the tensile strength of a standard anchor device. 
         [0045]    The first and the second anchor devices may be attached to additional anchor devices by any suitable methods known in the art, such as welding, wiring, screws, etc. Each anchor device may comprise a deformed steel bar that is attached or embedded in a concrete structure. The first and the second anchor devices are typically made of steel. However, the first and the second anchor devices may be made of any metal or structural material known in the art, such an alloy, iron, composites, etc. Further, the first and the second anchor devices typically have a cylindrical cross-section. In other embodiments, the first and the second anchor devices may have any geometrical cross-section, such as rectangular, triangular, etc. 
         [0046]    Additionally, the male and female ends are typically affixed to the first and the second anchor devices by welding, casting, crimping, or other methods known to one of skill in the art. In some embodiments, the male end has a tapered end. In other embodiments, the male end has a blunt end. Furthermore, the female end typically has an outer diameter greater than an outer diameter of the first anchor device. However, in an alternative embodiment, the female end may have an outer diameter substantially equal to the outer diameter of the first anchor device such that the female end is flush with the first anchor device. Further, the concrete structures that are connected by the quick connect coupling assembly may include concrete reinforcement bars, such as a rebar mat, or the concrete structures may be a structure without any concrete reinforcement bars. 
         [0047]    In another embodiment, a quick connect coupling assembly may include a first anchor device with a first shaped end and a second anchor device with a second shaped end. The first shaped end and the second shaped end are constructed and arranged to mate together to form the coupling assembly. It should be noted that neither the first shaped end nor the second shaped end is arranged as a male end or a female end as in the other embodiments set forth herein. The first and second shaped ends include mating shaped surfaces that engage upon contact or by rotating one of the anchor devices relative to the other anchor device. The first and second shaped ends may be complementary opposites. For instance, each shaped end may include a semi-circular outer surface with a curved inner surface that is configured to mate with the other complementary opposite shaped end. The first and second shaped ends may be identical. For instance, each shaped end may include a cylinder shape with a flat end face having a plurality of protrusions and a plurality of holes that mate the other identical shaped end. Even though, the first and second shaped ends have been described as semi-circular or cylindrical, it should be understood, however, that the first and second shaped ends may be any number geometrical shapes without departing from principles of the present invention. Similar to other embodiments, the coupling assembly is configured to connect adjacent concrete structures. The concrete structures may be used in roadways, streets and highways. The first anchor device includes a portion that will be attached or embedded in one concrete structure, and the second anchor device includes a portion that will be attached or embedded in another adjacent concrete structure. 
         [0048]    While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.