Patent Publication Number: US-7905068-B2

Title: Protective cap for coupler bar

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to methods and apparatus for protecting couplings that are used to interconnect adjacent sections of concrete structures. More specifically, the present invention relates to a protective cap for a coupler bar. 
     2. Description of the Related Art 
     Many steel-reinforced concrete structures are constructed in phases where one section of the concrete structure is constructed at a time. Each section generally includes steel reinforcing members that are to be interconnected to adjacent sections so as to improve the structural rigidity of the concrete structure. Many of these interconnections are made by a specially designed coupling that is mounted to a coupler bar. The coupler bar is integrated into the steel reinforcement framework of the concrete structure. As the concrete structure is formed, the coupler bars and couplings are typically covered in concrete. 
     After the section is poured, but before the concrete sets, each coupling has to be located so that the concrete can be removed from an area directly adjacent to the coupling. Clearing the concrete from the coupling is often achieved by applying a stream of pressurized water to wash away the concrete immediately surrounding the coupling. Locating each coupling and clearing the surrounding concrete are both highly labor intensive tasks. 
     Some couplings are furnished with some sort of protective cover. The protective cover attempts to limit damage to the coupling and limit intrusion of concrete into the coupling during construction. Although these protective covers help prevent damage to the coupling, removal of the protective covers further increases the time needed to expose the coupling as the covers can not be removed until the surrounding cement has been cleared. 
     Once the coupling has been located, the surrounding concrete cleared, and the protective cover removed, then the steel reinforcement from the next section can be connected to the coupling. It can be seen that the process for preparing the couplings often involves a lot of manual labor, which increases the cost and time needed to complete a project. Thus, the embodiments of the present invention are directed to methods and apparatus for protecting and preparing a coupling that seeks to overcome these limitations. 
     SUMMARY OF THE INVENTION 
     The present invention generally relates to methods and apparatus for protecting a coupling that is disposable within a concrete structure. In one aspect, a cap for engaging a coupling of a cement coupler bar is provided. The cap includes a body having an engagement portion and a back portion, wherein the engagement portion is configured to engage the coupling of the cement coupler bar. Additionally, the cap includes a flexible tail having a first end and a second end, wherein the first end is attached to the back portion of the body. 
     In another aspect, a method of using a protective cap with a coupling of a cement coupler bar is provided. The method includes the step of placing the protective cap adjacent the coupling of the cement coupler bar, wherein the protective cap comprises a body and a flexible tail. Further, the method includes covering the coupler bar, the coupling, and the protective cap with cement to form a cement structure, wherein the flexible tail of the protective cap at least partially extends from an outside surface of the cement structure. Additionally, the method includes the step of pulling on the flexible tail to remove the protective cap from cement structure and exposing a portion of the coupling. 
     In a further aspect, a coupler bar assembly for use in reinforcing a cement structure is provided. The coupler bar assembly includes a reinforcing bar with a coupling at an end thereof. Additionally, the coupler bar assembly includes a cap comprising a body and a flexible tail having a first end and a second end, wherein the first end is attached to a portion of the body. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       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. 
         FIG. 1  is an isometric view illustrating a protective cap in accordance with embodiments of the invention. 
         FIG. 2  is a view illustrating a coupler bar with the protective cap in accordance with embodiments of the invention. 
         FIG. 3  is a partial sectional view illustrating the protective cap disposed in a concrete structure. 
         FIG. 4  is a view illustrating the concrete structure of  FIG. 3  after the protective cap has been removed. 
         FIG. 5  is a partial sectional view illustrating the coupling with the protective cap in accordance with embodiments of the invention. 
         FIG. 6  is a partial sectional view illustrating the coupling with the protective cap in accordance with embodiments of the invention. 
         FIG. 7  is a partial sectional view illustrating the protective cap in accordance with embodiments of the invention. 
         FIG. 8  is a partial sectional view illustrating the protective cap in accordance with embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     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. 
     Referring now to  FIG. 1 , a protective cap  100  is illustrated in accordance with embodiments of the invention. The cap  100  generally comprises a body  105  and a flexible tail  110 . The body  105  includes a flange  130  and a plug  135  having an engagement portion. The flexible tail  110  includes a grip member  125 , such as a ring. The flexible tail  110  is coupled to the body  105  at a first end  115  and extends to a second end  120  to which the grip member  125  is connected. In one embodiment, the flexible tail  110  is at least three inches long from the first end  115  to the second end  120 . The flexible tail  110  typically has sufficient stiffness such that the second end  120  maintains a distance from the flange  130 , but does not break when deformed. The flexible tail  110  may be formed integral with the body  105  or may be separately coupled to the body, such as by adhesion or by a mechanical member, such as fasteners or pins. 
       FIG. 2  illustrates the protective cap  100  engaged in a coupler bar  10 . Generally, the coupler bar  10  comprises a reinforcing bar  20  and a coupling  25 . As shown, the coupling  25  is coupled to the reinforcing bar  20  at one end  15  and the protective cap  100  at an opposite end  30 . The protective cap  100  covers a receptacle (not shown) of the coupling  25 . In certain embodiments, the protective cap  100  is sealingly engaged with the coupling  25 . 
       FIG. 3  illustrates the coupler bar  10  and the protective cap  100  disposed in a concrete structure  50  in which the concrete has not set. As shown, the coupler bar  10  is disposed near an outside surface  55  of the concrete structure  50  to allow the interconnection of the coupler bar  10  with another reinforcing bar in an adjacent structure. As shown, when the concrete structure  50  is formed, the coupler bar  10  and the body  105  of the protective cap  100  are surrounded by concrete. 
     As the concrete structure  50  is formed, the protective cap  100  prevents concrete material from entering a receptacle  40  of the coupling  25 . In the embodiment shown, the plug  135  of the protective cap  100  has a conical shape that engages the internal threads  45  of the coupling  25 . As also shown in  FIG. 3 , the flexible tail  110  extends past the outside surface  55  of the concrete structure  50  so that the grip member  125  is visible and accessible from outside the concrete structure  50 . Depending on the methods used to form the concrete structure  50 , the flexible tail  110  and the grip member  125  may be folded over onto the outside surface  55  but is still visible and accessible from outside the concrete structure  50 . 
     After the concrete structure  50  is formed, but before the concrete is fully set, the protective cap  100  is removed by pulling the flexible tail  110 . Pulling the flexible tail  110  will disengage the plug  135  from the internal threads  45  of the coupling  25 , thus pulling the protective cap  100  from the coupling  25 . Importantly, as shown in  FIG. 4 , pulling the protective cap  100  from the coupling  25  may also displace the concrete between the coupling  25  and the outside surface  55  of the concrete structure  50  to form an opening  75  that exposes the coupling  25 . Once the coupling  25  is exposed, another threaded coupler bar can be coupled to the coupling  25 . 
     Thus, the protective cap  100  provides protection of the coupling  25  from damage or contamination while the concrete structure  50  is formed. Furthermore, the flexible tail  110  of the protective cap  100  allows for quick and easy locating and removal of the protective cap  100  after the concrete structure  50  has been formed. In addition, the protective cap  100  is capable of displacing the concrete between the coupling  25  and the outside surface  55  of the concrete structure  50  to form the opening  75  that exposes the coupling  25 . 
     The particular form and arrangement of a protective cap may depend on the type of coupling with which the cap interfaces. Therefore, it can be appreciated that any number of particular configurations of protective caps are possible. Similarly, the flexible tail may have any of a number of configurations that enhance identification and removal of a protective cap from outside of a particular concrete structure. 
     For instance,  FIG. 5  illustrates a protective cap  200  engaged with a coupling  65  of a coupling bar  60 . The protective cap  200  comprises a body  205  and a flexible tail  210 . The flexible tail  210  extends from the body  205  to an end  220  on which a tab  225  is disposed. The body  205  is configured to mate with a receptacle  70  of the coupling  65  and act as a plug in a similar manner as discussed herein. In one embodiment, the body  205  of the protective cap  200  is held in the receptacle  70  by friction. In another embodiment, the body  205  is affixed to the receptacle  70  by an adhesive or by some type of releasable mechanical attachment 
       FIG. 6  illustrates a protective cap  300  engaged with a coupling  85  of a coupling bar  80 . The protective cap  300  comprises a body  305  and a flexible tail  310 . The flexible tail  310  extends from the body  305  to an end  320  on which a ring  325  is disposed. The body  305  is affixed to the coupling  85  and covers the receptacle  90  but does not extend into the receptacle  90 . The body  305  may be affixed to the coupling  85  by an adhesive or by some type of releasable mechanical attachment to the outer surface of the coupling  85 . 
       FIGS. 7 and 8  illustrate embodiments of a flexible tail. In  FIG. 7 , a protective cap  400  comprises a flexible tail  410  having both ends  415  connected to a body  405  of the protective cap  400  to form a loop  425 . The loop  425  is sized such that the apex  440  is at a desired distance from a body  405  of the protective cap  400 . In  FIG. 8 , a protective cap  500  comprises a flexible tail  510  comprising a metal wire  540  and a metal loop  525 . A body  505  of the protective cap  500  may be formed from a plastic, such as injection-molded plastic or rubber material bonded to the flexible tail  510  or may be constructed of metal and otherwise coupled to the flexible tail  510 . Elastomeric, thermoplastics, or other compliant members may be also used in conjunction with an all metal protective cap to sealingly engage the coupling. 
     The embodiments of the present invention relate to methods and apparatus for protecting and providing access to a coupling disposed within a concrete structure. The present invention is susceptible to embodiments of different forms. There are shown in the drawings, and herein will be described in detail, specific embodiments of the present invention with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed below may be employed separately or in any suitable combination to produce desired results. 
     The embodiments set forth herein are merely illustrative and do not limit the scope of the invention or the details therein. It will be appreciated that many other modifications and improvements to the disclosure herein may be made without departing from the scope of the invention or the inventive concepts herein disclosed. Because many varying and different embodiments may be made within the scope of the inventive concept herein taught, including equivalent structures or materials hereafter thought of, and because many modifications may be made in the embodiments herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative and not in a limiting sense.