# US 11,725,387 B2 · Coupling device, associated parts and a method of use thereof > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,725,387 B2 - Document ID: US11725387B2 - Status: Granted - Kind: B2 - Application number: 17/724,266 - Filed: 2022-04-19 - Published: 2022-10-13 - Granted: 2023-08-15 - Earliest claimed: 2016-09-12 - Assignees: Coupler Solutions Limited - Applicants: Coupler Solutions Limited - Inventors: Christopher James Allington; Andrew Karl Diehl; Peter John Scott; Benjamin Woods; James Gray Gibson - Web page: https://patentgrep.com/patent/US11725387B2 ## CPC - E04C 5/165: {Coaxial connection by means of sleeves} - E04C: STRUCTURAL ELEMENTS; BUILDING MATERIALS (for bridges E01D; specially designed for insulation or other protection E04B; elements used as building aids E04G; for mining E21; for tunnels E21D; structural elements with broader range of application than for building engineering F16, particularly F16S) ## Abstract Described herein is a coupling device, associated parts and a method of use thereof. In one aspect, a coupling device is described comprising a sleeve with an inner surface that encloses at least part of at least one elongated element to be coupled; and at least one deformation means fitted with interference between, and causing local deformation about, at least part of the inner surface of the sleeve and/or an adjacent outer surface of the at least one elongated element. A deformation means insertion tool, a coupling sleeve, a deformation means, and a method of coupling at least one element are also described. The described coupling device, associated parts and a method of use offer the ability to couple together different elements in a strong and/or ductile manner, coupling being tuneable as needed to suit the preferred application. The coupling described may overcome art issues associated with bulky size of coupling, in particular, radial protrusion. The coupling may also increase the coupling force therefore increase the load that may be managed across the coupling device. Further, the way the parts are assembled may minimise generation of localised points of stress therefore also increasing the load that may be managed across the coupling device. ## Claims ### Claim 1 A reinforcing bar coupling assembly comprising: a sleeve with an inner surface that encloses at least part of at least one reinforcing bar when coupled with the at least one reinforcing bar; and at least one pin having a body and two opposing ends fitted with interference between, and causing: local plastic deformation about, at least part of the inner surface of the sleeve; local plastic deformation about, at least part of an adjacent outer surface of the at least one reinforcing bar; or local plastic deformation about, at least part of the inner surface of the sleeve and an adjacent outer surface of the at least one reinforcing bar; when coupled with the at least one reinforcing bar, where at least part of the body of the at least one pin is in contact with at least part of the inner surface of the sleeve and the outer surface of the at least one reinforcing bar when coupled with the at least one reinforcing bar and wherein local plastic deformation results in mechanical interlocking of the coupling assembly; and wherein the at least one pin is inserted tangentially and orthogonally to the longitudinal length of the at least one reinforcing bar between the inner surface of the sleeve and the adjacent outer surface of the at least one reinforcing bar when coupled with the at least one reinforcing bar. ### Claim 2 (depends on 1) The reinforcing bar coupling assembly as claimed in claim 1 wherein adhesive is located between the inner surface of the sleeve and the outer surface of the at least one reinforcing bar, the adhesive fusing and/or bonding the at least one pin and either, or both, the inner surface of the sleeve, or the outer surface of the at least one reinforcing bar. ### Claim 3 (depends on 2) The reinforcing bar coupling assembly as claimed in claim 2 wherein the adhesive is selected from: chemical adhesive, flux, metal plating, alloying elements, and chemical bonding. ### Claim 4 (depends on 1) The reinforcing bar coupling assembly as claimed in claim 1 wherein the at least one pin and sleeve inner surface and/or at least one reinforcing bar outer surface are configured to provide a camming action of the at least one pin relative to the sleeve inner surface and/or at least one reinforcing bar outer surface, as axial displacement occurs between the at least one reinforcing bar and sleeve during axial loading of the reinforcing bar coupling assembly. ### Claim 5 (depends on 4) The reinforcing bar coupling assembly as claimed in claim 4 wherein the camming action increases interference between the at least one pin and the at least one reinforcing bar. ### Claim 6 (depends on 4) The reinforcing bar coupling assembly as claimed in claim 4 wherein the camming action decreases interference between the at least one pin and the at least one reinforcing bar. ### Claim 7 (depends on 4) The reinforcing bar coupling assembly as claimed in claim 4 wherein the camming action results in rotation of the at least one pin on application of an axial force, embedding an edge of the at least one pin further into the at least one reinforcing bar. ### Claim 8 A method of assembling a reinforcing bar coupling assembly comprising: providing a sleeve with an inner surface; inserting at least part of at least one reinforcing bar into the sleeve so that the inner surface of the sleeve encloses at least part of the at least one reinforcing bar; and fitting with interference, at least one pin having a body and two opposing ends between the sleeve and at least one reinforcing bar, causing: local plastic deformation about, at least part of the inner surface of the sleeve; local plastic deformation about, at least part of an adjacent outer surface of the at least one reinforcing bar; or local plastic deformation about, at least part of the inner surface of the sleeve and an adjacent outer surface of the at least one reinforcing bar; wherein, once fitted, at least part of the body of the at least one pin is in contact with at least part of the inner surface of the sleeve and an outer surface of the at least one reinforcing bar and wherein local plastic deformation results in mechanical interlocking of the coupling assembly; and wherein the at least one pin is fitted tangentially and orthogonally to the longitudinal length of the at least one reinforcing bar between the inner surface of the sleeve and the adjacent outer surface of the at least one reinforcing bar. ### Claim 9 A coupler configured to couple together reinforcing bar ends, the coupler comprising: a sleeve with an inner surface that encloses, coaxially, an end of a reinforcing bar to be coupled; and an array of pins configured to mechanically interlock the sleeve and reinforcing bar end, the pins fitted, with interference, tangentially and generally orthogonally to the longitudinal length of the reinforcing bar end, between the sleeve inner surface and reinforcing bar end so that the pins in the array, on fitting, cause local-plastic deformation about part of an outer surface of the reinforcing bar end. ### Claim 10 (depends on 9) The coupler as claimed in claim 9 wherein adhesive is located between the inner surface of the sleeve and the outer surface of the at least one reinforcing bar, the adhesive fusing and/or bonding the at least one pin and either, or both, the inner surface of the sleeve, or the outer surface of the at least one reinforcing bar. ### Claim 11 (depends on 10) The coupler as claimed in claim 10 wherein the adhesive is present in the sleeve prior to fitment of the at least one reinforcing bar into the sleeve. ### Claim 12 (depends on 10) The coupler as claimed in claim 10 wherein the adhesive is applied between the sleeve and the at least one reinforcing bar after fitment of the at least one reinforcing bar into the sleeve. ### Claim 13 (depends on 9) The coupler as claimed in claim 9 wherein the at least one pin and sleeve inner surface and/or at least one reinforcing bar outer surface are configured to provide a camming action of the at least one pin relative to the sleeve inner surface and/or at least one reinforcing bar outer surface, as axial displacement occurs between the at least one reinforcing bar and sleeve during axial loading of the reinforcing bar coupling assembly. ### Claim 14 (depends on 13) The coupler as claimed in claim 13 wherein the camming action increases interference between the at least one pin and the at least one reinforcing bar. ### Claim 15 (depends on 13) The coupler as claimed in claim 13 wherein the camming action decreases interference between the at least one pin and the at least one reinforcing bar. ### Claim 16 (depends on 13) The coupler as claimed in claim 13 wherein the camming action results in rotation of the at least one pin on application of an axial force, embedding an edge of the at least one pin further into the at least one reinforcing bar. ### Claim 17 (depends on 13) The coupler as claimed in claim 13 wherein at least one pin in the array, prior to fitting, has a generally straight elongated and slender form along its body and two opposing ends and, at least one further pin in the array, prior to fitting, has a shape configured to provide a camming action. ### Claim 18 A method of coupling a reinforcing bar to a coupler, the method comprising the steps of: providing a coupler in the form of a sleeve having an inner surface; inserting an end of a reinforcing bar to be coupled into the sleeve, the reinforcing bar end being coaxially aligned with a longitudinal axis of the coupler sleeve; and fitting an array of pins, with interference, tangentially and generally orthogonally to the longitudinal length of the reinforcing bar, between the sleeve interior face and reinforcing bar end, so that the pins in the array cause local-plastic deformation about part of an outer surface of the reinforcing bar, the pin array mechanically interlocking the sleeve and reinforcing bar end together. ### Claim 19 (depends on 18) The method as claimed in claim 18 wherein prior to fitment of the at least one reinforcing bar into the sleeve, adhesive is located between the inner surface of the sleeve and the outer surface of the at least one reinforcing bar, the adhesive configured to fuse and/or bond the at least one pin and either, or both, the inner surface of the sleeve, or the outer surface of the at least one reinforcing bar. ### Claim 20 (depends on 18) The method as claimed in claim 18 wherein the at least one pin and sleeve inner surface and/or at least one reinforcing bar outer surface are configured to provide a camming action of the at least one pin relative to the sleeve inner surface and/or at least one reinforcing bar outer surface, as axial displacement occurs between the at least one reinforcing bar and sleeve during axial loading of the reinforcing bar coupling assembly.