Coupler system for reinforced concrete

Abstract

A coupler system for concrete structures can include a coupler and a flange attachment. The coupler can secure a first rebar at the first end of the coupler and can include an internal cavity with an opening at a second end of the coupler to receive a second rebar in an axial direction. The flange attachment can be secured to the second end of the coupler with one or more first protrusions that extend into the opening to secure the flange attachment to the coupler. A flange portion of the flange attachment can extend radially, relative to the axial direction, beyond an outer diameter of the coupler. A passage through the flange portion can be aligned with the opening of the coupler along the axial direction.

What is claimed is: 
     
         1 . A method of forming a concrete deck or other concrete structure, the method comprising:
 securing a coupler system to a concrete form, including:
 securing a flange portion of a flange attachment of the coupler system to the concrete form, to secure the flange attachment to the concrete form; and 
 extending one or more first protrusions of the flange attachment into an opening of a coupler of the coupler system, to secure the coupler to the flange attachment with: a passage through the flange portion being aligned with the opening of the coupler along an axial direction, and the flange portion extending, relative to the axial direction, radially beyond an outer diameter of the coupler; 
   with the flange portion secured to the concrete form to secure the coupler to the form via the flange attachment and the one or more first protrusions, and with the coupler securing a first rebar at a first end of the coupler, pouring a first quantity of concrete over a first area to cover the first rebar and the coupler system, including the flange attachment and the coupler; and   after the first quantity of concrete is set:
 removing the concrete form from the coupler system, with the flange attachment remaining secured to the coupler; 
 passing a second rebar through the passage and the opening of the coupler into an internal cavity of the coupler; and 
 pouring a second quantity of concrete over a second area adjacent to the first area, so that the second quantity of concrete covers the second rebar. 
   
     
     
         2 . The method of  claim 1 , wherein the flange attachment further includes one or more second protrusions that extend to receive part of the second quantity of concrete outside of the coupler, to anchor the flange attachment within the concrete with the flange attachment secured to the coupler by the one or more first protrusions. 
     
     
         3 . The method of  claim 1 , further comprising:
 after the second quantity of concrete is set, adding grout to the internal cavity to secure the second rebar within the coupler.   
     
     
         4 . The method of  claim 3 , wherein the second quantity of concrete sets to define a gap between the first quantity of concrete and the second quantity of concrete; and
 wherein the method further comprises, after the second quantity of concrete is set, closing the gap with grout.   
     
     
         5 . The method of  claim 1 , wherein passing the second rebar through the passage includes passing the second rebar through a seal member that at least partially covers the passage. 
     
     
         6 . The method of  claim 5 , wherein the seal member includes a central opening that receives the second rebar through the seal member and ribs arrayed around the central opening to support the second rebar within the opening relative to the flange attachment. 
     
     
         7 . The method of  claim 1 , wherein the flange attachment is secured to the coupler after the flange attachment is secured to the concrete form. 
     
     
         8 . The method of  claim 1 , wherein the first rebar is threadedly secured to the first end of the coupler. 
     
     
         9 . A coupler system for concrete structures, the coupler system comprising:
 a coupler that secures a first rebar at a first end of the coupler and that includes an internal cavity and an opening at a second end of the coupler that receives a second rebar in an axial direction into the internal cavity to secure the second rebar within the internal cavity;   a flange attachment secured to the second end of the coupler, the flange attachment including:
 one or more first protrusions that extend into the opening of the coupler to secure the flange attachment to the coupler; and 
 a flange portion that extends, relative to the axial direction, radially beyond an outer diameter of the coupler, and includes a passage through the flange portion that is aligned with the opening of the coupler along the axial direction. 
   
     
     
         10 . The coupler system of  claim 9 , wherein the flange attachment further includes one or more second protrusions that extend to receive concrete poured around the outside of the coupler, to anchor the flange attachment within the concrete with the flange attachment secured to the coupler by the one or more first protrusions. 
     
     
         11 . The coupler system of  claim 9 , further comprising:
 a seal member that at least partially covers the passage to block entry of concrete into the coupler via the opening.   
     
     
         12 . The coupler system of  claim 11 , wherein the seal member includes a central opening that is aligned with the opening of the coupler along the axial direction to receive the second rebar through the seal member into the opening of the coupler. 
     
     
         13 . The coupler system of  claim 12 , wherein the seal member further includes ribs arrayed around the central opening to support the second rebar within the opening relative to the flange attachment. 
     
     
         14 . The coupler system of  claim 11 , wherein the seal member is a resilient member secured to the flange attachment to at least partially cover the passage. 
     
     
         15 . The coupler system of  claim 14 , wherein the seal member includes protrusions received into attachment openings on the flange attachment to secure the seal member in alignment with the passage. 
     
     
         16 . The coupler system of  claim 9 , wherein the flange attachment is secured to the coupler directly, without a separate fastener. 
     
     
         17 . The coupler system of  claim 16 , wherein the one or more first protrusions engage the coupler at the opening with a snap-fit engagement. 
     
     
         18 . The coupler system of  claim 9 , herein the flange portion includes pre-formed fastener holes to secure the flange attachment and the coupler to a concrete form. 
     
     
         19 . The coupler system of  claim 18 , wherein the pre-formed fastener holes include keyhole profiles. 
     
     
         20 . A method of forming a concrete deck or other concrete structure, the method comprising:
 securing a coupler system to a concrete form, including:
 securing to the concrete form a radially-protruding flange portion of a flange attachment of the coupler system, to secure the flange attachment to the concrete form; and 
 securing a coupler of the coupler system to the concrete form by resiliently engaging one or more first protrusions of the flange attachment with the coupler, within an opening of a coupler, to secure the coupler to the flange attachment; 
   with the coupler system secured to the concrete form, pouring a first quantity of concrete to cover the coupler system and a first rebar extending from the coupler system away from the concrete form; and   after the first quantity of concrete is set: removing the concrete form from the coupler system, with the flange attachment remaining secured to the coupler, passing a second rebar through the flange attachment and the opening of the coupler into an internal cavity of the coupler, and pouring a second quantity of concrete adjacent to the first quantity of concrete to cover the second rebar.