U.S. patent application number 17/445031 was filed with the patent office on 2022-02-17 for composite rebar for use with quick connect coupling.
The applicant listed for this patent is ALLIED MOULDED PRODUCTS, INC.. Invention is credited to Tony Baker, Aaron T. Herman.
Application Number | 20220049499 17/445031 |
Document ID | / |
Family ID | |
Filed Date | 2022-02-17 |
United States Patent
Application |
20220049499 |
Kind Code |
A1 |
Herman; Aaron T. ; et
al. |
February 17, 2022 |
COMPOSITE REBAR FOR USE WITH QUICK CONNECT COUPLING
Abstract
A composite rebar includes a cylindrical body having a
cylindrical opening formed therethrough from a first end to an
opposing second of the cylindrical body. The composite rebar is
formed from a fiber reinforced polymer. The opening is cylindrical
in shape and is arranged concentric with an outer circumferential
surface of the cylindrical body.
Inventors: |
Herman; Aaron T.; (Bryan,
OH) ; Baker; Tony; (Waterloo, IN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ALLIED MOULDED PRODUCTS, INC. |
Bryan |
OH |
US |
|
|
Appl. No.: |
17/445031 |
Filed: |
August 13, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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63065725 |
Aug 14, 2020 |
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International
Class: |
E04C 5/16 20060101
E04C005/16; E04C 5/07 20060101 E04C005/07 |
Claims
1. A rebar comprising: a cylindrical body having a longitudinally
extending opening formed therein, the opening configured to receive
a portion of a coupling therein.
2. The rebar of claim 1, wherein the cylindrical body is formed
from a composite.
3. The rebar of claim 2, wherein the composite is a fiber
reinforced polymer.
4. The rebar of claim 1, wherein the opening is cylindrical in
shape and is arranged concentric with an outer circumferential
surface of the cylindrical body.
5. The rebar of claim 1, wherein the opening includes a surface
feature for engaging the portion of the coupling.
6. The rebar of claim 5, wherein the surface feature has a pattern
repeating along a length of the rebar.
7. A rebar assembly comprising: at least two rebars, each of the
rebars including a cylindrical body having a longitudinally
extending opening formed therein; and a coupling including at least
two coupling shafts, each of the coupling shafts received into the
opening of one of the rebars.
8. The assembly of claim 7, wherein an inner circumferential
surface of the cylindrical body defining the opening includes a
surface feature interacting with the corresponding coupling
shaft.
9. The assembly of claim 7, wherein each of the coupling shafts
includes a plurality of tapered segments.
10. The assembly of claim 9, wherein each of the tapered segments
tapers radially inwardly when progressing in a direction towards a
distal end of a respective one of the coupling shafts.
11. The assembly of claim 10, wherein each of the tapered segments
has a constant decreasing slope.
12. The assembly of claim 10, wherein each of the tapered segments
has a variably decreasing slope.
13. The assembly of claim 7, wherein the coupling is configured to
couple a pair of axially aligned rebars.
14. The assembly of claim 13, wherein the coupling includes a main
cylindrical body, wherein each of the coupling shafts extend
axially from a respective end of the main body, and wherein the
main body has an outer diameter substantially equal to a diameter
of each of the rebars.
15. The assembly of claim 7, wherein the coupling is configured to
couple a pair of perpendicularly arranged rebars.
16. The assembly of claim 15, wherein the coupling includes an
elbow portion, the elbow divided into a pair of cylindrically
shaped portions, wherein each the coupling shafts extend axially
from a respective one of the cylindrically shaped portions such
that the coupling shafts extend perpendicularly with respect to
each other.
17. The assembly of claim 7, wherein each of the coupling shafts
includes a spacer.
18. A method of assembling a rebar assembly comprising the steps
of: providing a first rebar, the first rebar having a hole formed
therethrough; and attaching the first rebar to a coupling, the
coupling having a first coupling shaft configured to be received in
the hole of the rebar.
19. The method of claim 18, further including the step of attaching
a second rebar to the coupling, wherein the coupling has a second
coupling shaft configured to be received in the hole of the
rebar.
20. The method of claim 19, further including the step of arranging
the first rebar perpendicular with respect to the second rebar.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 63/065,725, filed on Aug. 14, 2020. The entire
disclosure of the above application is hereby incorporated herein
by reference.
FIELD
[0002] The present invention relates generally to a novel rebar
assembly, and more particularly, a rebar assembly including a rebar
and a quick connect coupling, wherein the rebar is formed from a
composite material and includes an axially extending opening
configured to receive a portion of the quick connect coupling
therein.
BACKGROUND OF THE INVENTION
[0003] The term "rebar" generally refers to a bar or rod used to
reinforce another structure such as a concrete structure. Because
concrete typically includes a greater strength under compression
than tension, the rebars may be typically added to the concrete
structure for increasing the tensile strength thereof when
subjected to certain loads, such as bending moments tending to
cause certain parts of the concrete structure to encounter tensile
stresses. It is also common for the outer cylindrical surface of
such rebars to be provided with ribs, lugs, indentations, or the
like in order to better bond to the concrete and prevent slippage
between the concrete and the rebars.
[0004] A plurality of the rebars may be arranged into a specific
configuration accounting for the shape and expected stresses
encountered by the corresponding concrete structure. The resulting
rebar assembly may include elongate portions and various corners or
turns to account for the corresponding shape of the concrete
structure.
[0005] Rebar has traditionally been formed from steel based
materials with each of the rebars provided as an elongate
cylindrical member. Such rebars are generally formed to have
standardized lengths and diameters that are then selected to
account for the design considerations of the corresponding concrete
structure. For example, steel based rebar is typically provided in
a variety of different standardized diameters with each of the
standardized diameters separated from one another by increments of
1/8 inch, wherein each different diameter is numbered to generally
correspond to the number of eighths of an inch utilized (i.e. 3
corresponds to 3/8 inch, 4 corresponds to 1/2 inch, 5 corresponds
to 5/8 inch, etc.). Additionally, such rebars may also be provided
in standardized increments of length, such as 10 foot increments.
The longstanding use of such standardized sizes of rebars has led
to the design of such concrete structures accounting for the use of
one or more of these standardized sizes.
[0006] A variety of different configurations of the rebars may be
necessary to account for various sizes and shapes of the
corresponding concrete structure. For example, it may be common for
the concrete structure to have a length requiring multiple of the
rebars to be aligned in parallel and linked to each other to carry
the load of the concrete structure in a desired manner. In order
for the load to be properly distributed between a pair of the
rebars, it may be necessary for an overlap to be present between
the pair of the rebars with respect to the length directions
thereof. For example, FIG. 1 shows a configuration wherein a first
rebar 3 is arranged parallel to and overlapped with a second rebar
4. The overlap length L present therebetween may typically be
selected to be about 40 times the diameter of each of the rebars
utilized in the pairing. This need for a coextensive overlap
therefore wastes material and increases the weight used and the
cost necessary to provide the desired reinforcement under such
circumstances.
[0007] Additionally, as shown in FIG. 2, there may be instances
wherein it may be desirable to bend or curve one or more of the
rebars to account for changes in the geometry of the corresponding
concrete structure. In FIG. 2, a rebar 5 is bent about 90 degrees
at a bent portion 6 thereof to create two perpendicular arranged
portions in the rebar 5. Such bending of the rebar 5 may increase
the time for installation and necessitate access to certain tools
or machinery for forming such bends in the otherwise rigid and
elongate rod forming the rebar 5. Additionally, such bends
introduce further tension along the exterior corner of the bent
portion 6, which may weaken the rebar 5 at the bent portion 6 due
to the resulting increase in strain.
[0008] In addition to being limited to standardized sizes, steel
based rebar also generally suffers from being corrosive, relatively
heavy, and conductive both thermally and electrically. With regards
to the corrosiveness thereof, it may be common for steel based
rebar to be epoxy resin coated to protect the outer surfaces
thereof from such corrosion. The use of such coatings adds cost and
complexity to the manufacturing process. The other listed
shortcomings also must be accounted for when designing the concrete
structures utilizing such steel based rebar.
[0009] It has become increasingly common to utilize alternative
materials such as composites in order to account for the
disadvantages of the previously described steel based rebar
assemblies. One suitable composite may be a fiber reinforced
polymer (FRP). The FRP rebar is non-corrosive, relatively light in
weight, and non-conductive in comparison to the steel based
counterparts. Additionally, such FRP rebar can be formed to have a
greater tensile strength for a given cross-sectional area in
comparison to steel based rebar. However, one potential
disadvantage of such composite based rebar may be the difficulty in
field modifying (bending or otherwise deforming) such composite
materials in order to account for certain design considerations of
the corresponding concrete structures.
[0010] There is accordingly a need for a composite based rebar that
is quickly and easily installed while also being capable of being
arranged or modified into any variety of different configurations.
There is also a need for a composite based rebar that reduces the
amount of material necessary due to the elimination of overlaps and
other splicing configurations, and especially in comparison to
similar configurations utilizing steel based rebar.
SUMMARY OF THE INVENTION
[0011] Consistent and consonant with the present invention, an
improved composite rebar assembly has surprisingly been
discovered.
[0012] According to an embodiment of the present disclosure, a
rebar is disclosed. The rebar includes a cylindrical body having a
longitudinally extending opening formed therein. The opening is
configured to receive a portion of a coupling therein.
[0013] According to another embodiment of the present disclosure, a
rebar assembly is disclosed. The rebar assembly includes at least
two rebars. Each of the rebars includes a cylindrical body having a
longitudinally extending opening formed therein. A coupling
includes at least two coupling shafts. Each of the coupling shafts
are received into the opening of one of the rebars.
[0014] According to yet another embodiment of the present
disclosure, a method of assembling a rebar assembly comprises the
step of providing a first rebar wherein the first rebar has a hole
formed therethrough. The method further includes the step of
attaching the first rebar to a coupling. The coupling has a first
coupling shaft configured to be received in the hole of the
rebar.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The above-mentioned, and other features and objects of the
inventions, and the manner of attaining them will become more
apparent and the invention itself will be better understood by
reference to the following description of an embodiment of the
invention taken in conjunction with the accompanying drawings,
wherein:
[0016] FIG. 1 is a schematic left side elevational view of a rebar
assembly according to the prior art having an overlap present with
respect to a pair of parallel arranged rebar structures;
[0017] FIG. 2 is a left side perspective view of a rebar structure
according to the prior art having a bent portion for forming a 90
degree angle within the rebar structure;
[0018] FIG. 3 is a top perspective view of a composite rebar
according to an embodiment of the present invention;
[0019] FIG. 4 is a left side elevational view of the composite
rebar of FIG. 3;
[0020] FIG. 5 is a top plan view of the composite rebar of FIG.
3;
[0021] FIG. 6 is a front elevational view of the composite rebar of
FIG. 3;
[0022] FIG. 7 is a left side elevational exploded view of a quick
connect coupling for use with the rebar of FIGS. 3-6 according to
an embodiment of the present invention, wherein the quick connect
coupling is configured to couple an axially aligned pair of the
rebars, and wherein inner features of the rebars are partially
shown with phantom lines;
[0023] FIG. 8 is a left side elevational exploded view of another
quick connect coupling for use with the rebar of FIGS. 3-6
according to another embodiment of the present invention, wherein
the quick connect coupling is configured to couple a perpendicular
arranged pair of the rebars, and wherein inner features of the
rebars are partially shown with phantom lines;
[0024] FIG. 9 is a left side elevational exploded view of a rebar
assembly including another quick connect coupling for use with the
rebar of FIGS. 3-6 according to another embodiment of the present
invention, wherein the quick connect coupling is shown as coupling
an axially aligned pair of the rebars, and wherein inner features
of the rebars are partially shown with phantom lines;
[0025] FIG. 10 is a chart equating standardized sizes of steel
rebar A-111 with standardized sizes of Glass Fiber Reinforced
Polymer (GFRP) rebar; and
[0026] FIG. 11 is a chart listing standardized dimensions of GFRP
rebar.
DETAILED DESCRIPTION OF AN EMBODIMENT
[0027] The following detailed description and appended drawings
describe and illustrate various exemplary embodiments of the
invention. The description and drawings serve to enable one skilled
in the art to make, and use the invention, and are not intended to
limit the scope of the invention in any manner. With respect to the
methods disclosed, the steps presented are exemplary in nature, and
thus, the order of the steps is not necessary or critical.
[0028] As used herein, substantially is defined as "to a
considerable degree" or "proximate" or as otherwise understood by
one ordinarily skilled in the art. Except where otherwise expressly
indicated, all numerical quantities in this description are to be
understood as modified by the word "about" and all geometric and
spatial descriptors are to be understood as modified by the word
"substantially" in describing the broadest scope of the technology.
"About" when applied to numerical values indicates that the
calculation or the measurement allows some slight imprecision in
the value (with some approach to exactness in the value;
approximately or reasonably close to the value; nearly). If, for
some reason, the imprecision provided by "about" and/or
"substantially" is not otherwise understood in the art with this
ordinary meaning, then "about" and/or "substantially" as used
herein indicates at least variations that may arise from ordinary
methods of measuring or using such parameters. Where any conflict
or ambiguity may exist between a document incorporated by reference
and this detailed description, the present detailed description
controls. Although the terms first, second, third, etc. may be used
herein to describe various elements, components, regions, layers
and/or sections, these elements, components, regions, layers and/or
sections should not be limited by these terms. These terms may be
only used to distinguish one element, component, region, layer or
section from another region, layer or section. Terms such as
"first," "second," and other numerical terms when used herein do
not imply a sequence or order unless clearly indicated by the
context. Thus, a first element, component, region, layer or section
discussed below could be termed a second element, component,
region, layer or section discussed below could be termed a second
element, component, region, layer. As used herein "configured to"
is a structural term and refers to the structure of the apparatus
being disclosed.
[0029] FIGS. 3-6 illustrate a novel composite rebar 10 according to
an embodiment of the present invention, which is referred to
hereinafter as the rebar 10 for brevity. The rebar 10 is formed
from a composite material including a resin and a filler material
or fiber. The rebar 10 may be formed from a Glass Fiber Reinforced
Polymer (GFRP) rebar. The GFRP may be formed from fiberglass in
conjunction with a plastic resin. However, other composites having
other combinations of fibers and resins may be utilized without
necessarily departing from the scope of the present invention. The
rebar 10 may be formed in a suitable molding process, as desired,
although other manufacturing processes may be utilized. If molding
is used, the rebar 10 may be initially provided as a fiber preform
received within a corresponding mold into which a molten resin
(thermoplastic) material is introduced and then cured to form the
desired shape and configuration of the rebar 10 with the fibers
positioned and oriented in a desired manner.
[0030] The rebar 10 is cylindrical in shape and extends
longitudinally from a first end 11 to an opposing second end 12
thereof. The rebar 10 further includes a cylindrical opening 13
formed therein with the opening 13 arranged co-axially and
concentrically relative to an outer surface of the cylindrical
rebar 10. The rebar 10 accordingly has the form of an elongate
hollow cylinder with a greater length than outer diameter. In a
provided example, the rebar 10 includes a nominal outer diameter
O.sub.OD of 0.5 inches while the opening 13 has a diameter O.sub.ID
of 0.19 inches (10-32 tapped hole). However, as explained in
greater detail hereinafter, the rebar 10 is preferably provided in
any number of a variety of standardized outer diameters and opening
diameters in addition to that shown and described. The rebar 10 may
also include any desired axial length, including being provided in
various inch or foot based increments. The composite forming the
rebar 10 may be selected to be field modified via a suitable
cutting or sawing tool to allow for the rebar 10 to be easily
adjustable to any desired axial length for the given application,
as desired.
[0031] The rebar 10 includes an interference pattern 14 formed on
an outer circumferential surface thereof. The interference pattern
14 may be provided as any configuration of ribs, lugs, projections,
indentations, or the like extending into or projecting outwardly
from the nominal outer circumferential surface for interacting with
any surrounding substance encasing the rebar 10, such as but not
limited to concrete poured around the rebar 10 when the rebar 10 is
used to reinforce a concrete structure. The interference pattern 14
accordingly prevents relative motion between the rebar 10 and the
encasing substance via the interfering engagement between the
various surfaces forming the interference pattern 14 and the
surfaces of the encasing substance adjacent the interference
pattern 14. In a provided example, the interference pattern 14 is
provided as a pair of diametrically opposed and longitudinally
repeating patterns 15 of X-shaped projections extending from the
nominal outer circumferential surface. The interference pattern 14
further includes a pair of diametrically opposed and longitudinally
extending ribs 16 positioned between the opposing patterns 15 of
the X-shaped projections with respect to a circumferential
direction of the rebar 10. However, one skilled in the art should
appreciate that the interference pattern 14 may take on any
configuration suitable for interacting with the surrounding
structure while remaining within the scope of the present
invention.
[0032] As shown in FIG. 6, an inner circumferential surface of the
rebar 10 defining the opening 13 may also include a surface feature
18 formed therein. The surface feature 18 may be formed by any
pattern of ribs, lugs, projections, indentations, or the like
extending into or projecting outwardly from the nominal inner
circumferential surface of the rebar 10 forming the opening 13. The
surface feature 18 may be provided to be repeated with respect to
the longitudinal direction of the rebar 10.
[0033] The rebar 10 may be formed to include a dual strain design.
The dual strain design may include the reinforcing fibers disposed
along each of the outer circumferential surface of the rebar 10 as
well as the inner circumferential surface defining the opening 13,
as one non-limiting example. The inner circumferential surface may
be wrapped with the fibers.
[0034] Referring now to FIGS. 7-9 various different quick connect
couplings 30, 40, 60 configured for use with a plurality of the
rebars 10 are disclosed. Each of the couplings 30, 40, 60 is
provided to form a connection between two adjacent ones of the
rebars 10 for forming a larger rebar assembly, respectively
referred to as reference numerals 300, 400, 600, suitable for
implementation into a concrete structure or similarly encased
structure.
[0035] The coupling 30 of FIG. 7, which may be referred to as a
butt connector, is utilized for coupling two of the rebars 10
having ends 11, 12 that are axially aligned and arranged in
parallel. The coupling 30 may accordingly be utilized for coupling
two elongate rebars 10 for forming a single one of the rebar
assembly 300 spanning a greater longitudinal length, thereby
allowing for any plurality of the rebars 10 to be coupled together
to span a desired length of the corresponding concrete structure.
The coupling 30 may be formed from a different material than the
corresponding rebars 10 coupled thereto, such as a metallic
material. The metallic material may be an aluminum alloy, such as
aluminum 6061. However, other metallic materials having similar
characteristics of strength, elasticity, and the like may also be
utilized.
[0036] The coupling 30 includes a primary body 32 and a pair of
coupling shafts 35. The primary body 32 extends axially from a
first end 33 to an opposing second end 34. One of the coupling
shafts 35 extends axially from each of the ends 33, 34 of the
primary body 32. The coupling shafts 35 and the primary body 32 are
arranged coaxially and concentrically. However, it is understood an
offset and non-concentric arrangement can be configured if
desired.
[0037] Each of the coupling shafts 35 is generally cylindrical in
shape and extends axially from a base 36 intersecting the
corresponding one of the ends 33, 34 of the primary body 32 to a
distal end 37 spaced axially from the base 36. Each of the coupling
shafts 35 may extend any suitable axial distance for establishing a
desired connection between each of the coupling shafts 35 and a
corresponding one of the rebars 10.
[0038] Each of the coupling shafts 35 includes a plurality of
tapered segments 38 repeated with respect to the axial direction of
the coupling 30. Each of the tapered segments 38 tapers radially
inwardly when progressing in a direction away from the
corresponding base 36 and towards the corresponding distal end 37.
Each of the tapered segments 39 tapers radially at a constant rate.
In the provided embodiment, each of the tapered segments 38 has the
configuration of a truncated cone, thereby resulting in each of the
coupling shafts 35 resembling a stacked assembly of the truncated
cones. Each of the coupling shafts 35 is configured to be received
into a corresponding opening 13 of one of the rebars 10, such as by
press-fitting. The tapered segments 38 are configured to provide a
one-way interference fit between each of the coupling shafts 35 and
the opening 13 into which the coupling shaft 35 is press-fit.
Specifically, a tapered conical surface 39 of each of the tapered
segments 38 is configured to slide relative to the inner
circumferential surface of the rebar 10 defining the opening 13
during axial entry of the coupling shaft 35 into the opening 13
while the surface 39, which is radially inwardly extending, of each
of the tapered segments 38 prevents axial removal of the coupling
shaft 35 from the opening 13 in a reverse direction away from the
restive ends 33, 34 od he primary body 32. The surface feature 18
formed on the inner circumferential surface defining the opening 13
may be shaped and dimensioned to facilitate this relationship with
respect to each of the axial directions of the coupling 30.
[0039] The primary body 32 of the coupling 30 may include an outer
diameter O.sub.ODC substantially corresponding to that of each of
the rebars 10 coupled thereto, such as 0.5 inches, to form a
substantially continuous and consistent outer diameter between the
coupled together rebars 10 and intervening coupling 30. Each of the
coupling shafts 35 may include an average diameter O.sub.avg
substantially corresponding to that of the opening 13, such as
about 0.19 inches, for example. It should be apparent that each of
the tapered segments 38 may generally include a maximum diameter
greater than a minimum diameter of the surface feature 18 of the
opening 13 to facilitate the ease of entry and difficulty or
removal of the coupling shafts 35 from the openings 13 as described
above. The primary body 32 may also be provided to include any
desired axial length L.sub.B, such as 1 inch (double the 0.5 inch
diameter), for example.
[0040] Although not shown, the different portions of the coupling
30 may be provided to be hollow to minimize the material utilized
in forming each of the couplings 30, as desired.
[0041] FIG. 7 illustrates an exploded view of the rebar assembly
300, the coupling shaft 35 of the coupling 30 adjacent the first
end 33 of the primary body 32 is received into the opening 13 of a
first one of the rebars 10 adjacent the second end 12 thereof while
a coupling shaft 35 adjacent the second end 34 of the primary body
32 is received into the opening 13 of a second one of the rebars 10
adjacent the first end 11 thereof. The second end 12 of the first
one of the rebars 10 is abutted against the first end 33 of the
primary body 32 while the first end 11 of the second one of the
rebars 10 is abutted against the second end 34 of the primary body
62. The one-way interference fit provided between each of the
openings 13 and each of the coupling shafts 35 then prevents
undesired removal of each of the coupling shafts 35 from the
corresponding first and second rebars 10.
[0042] The coupling 40 of FIG. 8 is similar to the coupling 30 in
many respects, but is instead configured for coupling two
perpendicular arranged rebars 10 for forming a 90 degree joint
therebetween to form the rebar assembly 400. The coupling 40
includes an elbow portion 42 and a pair of coupling shafts 55
projecting from perpendicular arranged surfaces 45, 46 of the elbow
portion 42. The perpendicular arranged surfaces 45, 46 are formed
in cylindrically shaped segments 43, 44 of the elbow portion 42
arranged perpendicular to each other.
[0043] Each of the coupling shafts 55 extends axially from a base
56 to a distal end 57. In contrast to the coupling shafts 35 of
FIG. 7, each of the coupling shafts 55 includes a cylindrical
spacer 59 immediately adjacent the elbow portion 42 to space the
corresponding tapered segments 58 from the elbow portion 42. The
spacing of the tapered segments 58 via the corresponding
cylindrical spacer 59 may be necessary to account for the
interaction between the ends 11, 12 of the rebars 10 at a distance
spaced from the elbow portion 42 due to the perpendicular
arrangement therebetween. The tapered segments 58 are also shown as
having a slightly different taper from the truncated conical
tapered segments 38 of FIG. 7, but still operate in the same
fashion. Specifically, the tapered segments 58 include a variably
decreasing slope as the tapered segments 58 extend axially away
from the base 56 to form concave surfaces in each of the tapered
segments 58. It should be apparent that each of the couplings 30,
40 may include either of the configurations of the tapered segments
38, 58 without significantly altering the use thereof.
[0044] FIG. 8 illustrates an exploded view of the rebar assembly
400, the coupling shaft 55 (i.e. the vertical one of the shafts 55)
of the coupling 40 adjacent the surface 46 of the elbow portion 32
is received into the opening 13 of a first one of the rebars 10
adjacent the second end 12 thereof while the coupling shaft 55
(i.e. the horizontal one of the shafts 55) adjacent the surface 45
of the elbow portion 42 is received into the opening 13 of a second
one of the rebars 10 adjacent the first end 11 thereof. Due to the
spacers 59 of the coupling shafts 55, one or both the first one of
the rebars 10 or the second one of the rebars 10 may abut the
respect surfaces 45,46 or be spaced from the respect surfaces 45,
46 to militate against interference of the rebars 10. The one-way
interference fit provided between each of the openings 13 and each
of the coupling shafts 55 then prevents undesired removal of each
of the coupling shafts 55 from the corresponding first and second
rebars 10.
[0045] FIG. 9 illustrates a coupling 60 that is substantially
identical to the coupling 30 except for a significant elongation of
the primary body 62 thereof in comparison to the diameter of the
primary body 62. In the illustrated example, the primary body 62
has the axial length L.sub.B of 6 inches, for example, when
extending from a first end 63 to an opposing second end 64 thereof,
as well as a diameter of 0.5 inches, but other dimensions may be
utilized. The elongation of the primary body 62 is provided to
allow for the primary body 62 to be more easily deformed to
accommodate different configurations of the rebars 10. For example,
the primary body 62 could be bent about 45 degrees to facilitate
the connection of the coupling 60 to a pair of the rebars 10 also
arranged at a 45 degree angle relative to each other. The primary
body 62 may be bent or otherwise deformed into other
configurations, as desired.
[0046] FIG. 9 also illustrates the rebar assembly 600 assembled
with of a pair of the rebars 10 as would also be consistent with
use of either of the couplings 30, 40. A coupling shaft 65 of the
coupling 60 adjacent the first end 63 of the primary body 62 is
received into the opening 13 of a first one of the rebars 10
adjacent the second end 12 thereof while a coupling shaft 65
adjacent the second end 64 of the primary body 62 is received into
the opening 13 of a second one of the rebars 10 adjacent the first
end 11 thereof. The second end 12 of the first one of the rebars 10
is abutted against the first end 63 of the primary body 62 while
the first end 11 of the second one of the rebars 10 is abutted
against the second end 64 of the primary body 62. The one-way
interference fit provided between each of the openings 13 and each
of the coupling shafts 65 then prevents undesired removal of each
of the coupling shafts 65 from the corresponding first and second
rebars 10.
[0047] Although not illustrated, it should be apparent additional
coupling configurations may be utilized in conjunction with two or
more of the rebars 10 for forming any number of assemblies. For
example, the coupling 30, 40, 60 could include any angle of
inclination present between the coupling shafts 35, 55, 65 to
accommodate any angle between the adjoining rebars 10. Furthermore,
the coupling may be formed with three or more of the coupling
shafts 35, 55, 65 extending from a common structure, such as the
primary body 32, 62 or the elbow portion 42 to allow for any
variety of different configurations of three or more of the rebars
10, such as a cross-shape having four of the coupling shafts 35,
55, 65.
[0048] As mentioned throughout, the rebars 10 and the corresponding
couplings 30, 40, 60 may be provided to include any number of
different dimensions without departing from the scope of the
present invention. However, it may be preferable to produce the
rebars 10 to have the standardized diameters that are common to
already utilized steel or GFRP rebars to allow for an easy
substitution of the rebars 10 and couplings 30, 40, 60 of the
current invention in place of exiting solutions. For example, FIGS.
10 and 11 include some common standardized sizes of both steel
based and GFRP based rebars that may be emulated so that such
substitutions can be made without having to significantly redesign
exiting models or the like.
[0049] The diameter O.sub.ID of the opening 13 included along the
central axis of each of the rebars 10 may also be selected to allow
for the each of the rebars 10 to have characteristics similar to or
improving upon the standardized sizes utilized for existing steel
based or GFRP based rebars devoid of such openings. For example,
because GFRP has a greater tensile strength than steel, the
diameter OD of the opening 13 relative to the outer circumferential
surface of the rebar 10 may be selected so that the rebar 10 has at
least the same or greater tensile strength than a steel rebar
having the same outer diameter. For example, the illustrated 0.5
inch diameter O.sub.OD rebar 10 having the 0.19 inch diameter
O.sub.ID opening 13 still has a greater tensile strength than a
corresponding 0.5 inch steel rebar devoid of any type of opening or
hollowing out. Alternatively, the inner diameter O.sub.ID of the
opening 13 may be selected so that each incremental outer diameter
option for the rebar 10 of the present invention is at least as
strong or stronger than an adjacent option for an GFRP rebar devoid
of such an opening. For example, with reference to FIG. 11, a #3
(inch) GFRP rebar devoid of an opening has a cross-sectional area
of 0.110 inches squared, whereas the example rebar 10 has the outer
diameter O.sub.OD corresponding to a #4 GFRP rebar while still
having a cross-sectional area of 0.168 square inches. The
illustrated rebar 10 having the #4 sized diameter accordingly
includes a greater tensile strength (as based on the
cross-sectional area) than a corresponding GFRP rebar one
standardized size (#3) smaller than the rebar 10 according to the
example. In fact, the opening 13 could have a diameter O.sub.ID as
great as 0.33 inches while maintaining the same cross-sectional
area and hence strength for the #4 versus #3 comparison. As such,
the rebar 10 of the present invention at any of the standardized
sizes may be substituted for another standardized size of the GFRP
rebar while maintaining at least the same strength thereof.
[0050] The rebar assembly 300, 400, 600 utilizing the rebars 10 and
couplings 30, 40, 60 of the present invention accordingly provides
numerous advantages over the rebar assemblies of the prior art. The
inclusion of the opening 13 reduces material usage while
maintaining strength. The inclusion of the opening 13 also allows
for the couplings 30, 40, 60 to be utilized for forming any number
of configurations of the rebars 10, which eliminates the need for
overlaps to be present between the rebars 10 as is typical of
traditional rebar assemblies. This lack of overlap further reduces
the material usage of the rebar assembly 300, 400, 600. The variety
of different possible couplings 30, 40, 60 also facilitates an ease
of assembly and versatility of the possible rebar assemblies
without requiring field modification to the rebars 10 (such as
bending). Additionally, in comparison to steel, the use of the
composite rebar 10 provides increased strength, the ability for the
selection of different fibers for a given application, and the
ability to use recycled materials in forming the rebar assembly
300, 400, 600.
[0051] From the foregoing description, one ordinarily skilled in
the art can easily ascertain the essential characteristics of this
invention and, without departing from the spirit and scope thereof,
can make various changes and modifications to the invention to
adapt it to various usages and conditions.
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