Bayonet duct coupler assembly for post-tensioned concrete member

1. A duct coupler assembly for use in post-tensioning concrete comprising:

a female duct coupler, the female duct coupler coupled to a first duct segment, the female duct coupler including a female duct coupler body having a longitudinally facing female edge and an inner surface having an inner diameter, the female duct coupler having a bayonet slot; and

a male duct coupler, the male duct coupler coupled to a second duct segment, the male duct coupler including a male duct coupler body having an outer surface having an outer diameter, the outer diameter smaller than the inner diameter of the inner surface of the female duct coupler body, the male duct coupler having a bayonet post extending from an outer surface of the male duct coupler body, the male duct coupler being coupled with the female duct coupler wherein a portion of the male duct coupler body is positioned within the female duct coupler body and the bayonet post is positioned within the bayonet slot, wherein the bayonet post contacts a detent or flat formed in the bayonet slot and wherein the detent or flat retains the bayonet post by elastic tension between the female duct coupler body and the male duct coupler body;

wherein the male duct coupler further comprises a male coupler flange defining a longitudinally facing male edge, the longitudinally facing male edge abutting the longitudinally facing female edge of the female duct coupler when the male duct coupler is coupled with the female duct coupler so as to resist further insertion of the male duct coupler body into the female duct coupler body.

2. The duct coupler assembly of claim 1 , wherein the female duct coupler further comprises an inner flange, the inner flange positioned within the female duct coupler body, the inner flange and female duct coupler body defining a seal groove therebetween, the seal groove being capable of receiving a male edge of the male duct coupler body.

3. The duct coupler assembly of claim 2 , further comprising a seal positioned within the seal groove.

4. The duct coupler assembly of claim 1 , wherein the female duct coupler is coupled to the first duct segment and the male duct coupler is coupled to the second duct segment by press fitting, mechanical welding, chemical welding, friction welding, thermal coupling, thermal welding, a shrink sleeve, an O-ring or diametric seal, or an adhesive.

5. The duct coupler assembly of claim 4 , wherein the female duct coupler is coupled to the first duct segment and the male duct coupler is coupled to the second duct segment by press fitting, chemical welding, friction welding, thermal coupling, thermal welding, a shrink sleeve, an O-ring or diametric seal, or an adhesive.

6. The duct coupler assembly of claim 1 , wherein the first and second duct segments are duct.

7. The duct coupler assembly of claim 1 , wherein a tensioning member is threaded through the male and female duct couplers.

8. The duct coupler assembly of claim 1 , wherein the female duct coupler and male duct coupler are separably coupleable.

9. The duct coupler assembly of claim 1 , wherein at least one of the duct couplers is formed integrally as an end of the first or second duct segments.

10. The duct coupler of claim 1 , wherein the bayonet slot has a helical path.

11. A duct coupler assembly comprising,

a female duct coupler, the female duct coupler coupled to a first duct segment, the female duct coupler including a female duct coupler body having a longitudinally facing female edge and an inner surface having an inner diameter, the female duct coupler having a bayonet slot; and

a male duct coupler, the male duct coupler coupled to a second duct segment, the male duct coupler including a male duct coupler body having an outer surface having an outer diameter, the outer diameter smaller than the inner diameter of the inner surface of the female duct coupler body, the male duct coupler having a bayonet post extending from an outer surface of the male duct coupler body, the male duct coupler being coupled with the female duct coupler wherein a portion of the male duct coupler body is positioned within the female duct coupler body and the bayonet post is positioned within the bayonet slot;

wherein the male duct coupler further comprises a male coupler flange defining a longitudinally facing male edge, the longitudinally facing male edge abutting the longitudinally facing female edge of the female duct coupler when the male duct coupler is coupled with the female duct coupler so as to resist further insertion of the male duct coupler body into the female duct coupler body;

wherein the first duct segment is positioned within a first concrete element and the second duct segment is positioned within a second concrete element.

12. The duct coupler assembly of claim 11 , wherein the second concrete element is formed about the second duct segment after the second duct segment is coupled to the first duct segment.

13. A method comprising:

forming a first concrete element, the first concrete element having a first duct segment positioned therein and extending from an end of a first concrete element;

positioning a form adjacent to the end of the first concrete element;

providing a duct coupler assembly, the duct coupler assembly including:

a female duct coupler, the female duct coupler including a female duct coupler body having an inner surface having an inner diameter, the female duct coupler having a bayonet slot, the female duct coupler body having a longitudinally facing female edge; and

a male duct coupler, the male duct coupler including a male duct coupler body having an outer surface having an outer diameter, the outer diameter smaller than the inner diameter of the inner surface of the female duct coupler body, the male duct coupler having a bayonet post extending from an outer surface of the male duct coupler body, wherein the male duct coupler further comprises a male coupler flange defining a longitudinally facing male edge;

coupling the female duct coupler of the duct coupler assembly to the first duct segment;

coupling the male duct coupler of the duct coupler assembly to a second duct segment;

coupling the second duct segment to the first duct segment by:

inserting the male duct coupler into the female duct coupler such that the bayonet post enters the bayonet slot, the longitudinally facing male edge abutting the longitudinally facing female edge of the female duct coupler, so as to resist further insertion of the male duct coupler body into the female duct coupler body; and

rotating the second duct segment to retain the bayonet post in the bayonet slot; and

pouring concrete into the form to form a second concrete element having the second duct section positioned therein.

14. The method of claim 13 , wherein the first and second duct couplers are coupled to the first and second duct segments respectively by press fitting, mechanical welding, chemical welding, friction welding, thermal coupling or welding, using a shrink sleeve, using an O-ring or diametric seal, or using one or more adhesives.

15. The method of claim 13 , wherein the step of rotating the second duct segment further comprises locking the male duct coupler to the female duct coupler.

16. The method of claim 13 , wherein the duct coupler assembly further comprises a seal positioned within a seal groove.

17. The method of claim 16 , further comprising sealing the female duct coupler to the male duct coupler.

18. The method of claim 13 , wherein the step of rotating the second duct segment to engage the bayonet post into the bayonet slot is performed along a generally helical path.

19. The method of claim 13 further comprising contacting the bayonet post with a detent or flat formed in the bayonet slot.

20. The method of claim 19 , further comprising retaining the bayonet post by elastic tension.

21. A duct coupler assembly for use in post-tensioning concrete comprising:

a female duct coupler, the female duct coupler coupled to a first duct segment, the female duct coupler having a longitudinally facing female edge and a bayonet slot; and

a male duct coupler, the male duct coupler coupled to a second duct segment, the male duct coupler having a bayonet post extending from an outer surface of the male duct coupler, the male duct coupler separably coupled to the female duct coupler, at least a portion of the male duct coupler positioned within the female duct coupler, and the bayonet post positioned within the bayonet slot wherein the bayonet post contacts a detent or flat formed in the bayonet slot and wherein the detent or flat retains the bayonet post by elastic tension between the female duct coupler body and the male duct coupler body;

wherein the male duct coupler further comprises a male coupler flange defining a longitudinally facing male edge, and wherein the longitudinally facing male edge abuts the longitudinally facing female edge when the male duct coupler is coupled with the female duct coupler so as to resist further insertion of the male duct coupler body into the female duct coupler body.

22. The duct coupler assembly of claim 21 , wherein the female and male duct couplers are coupled to the first and second duct segments respectively by press fitting, mechanical welding, chemical welding, friction welding, thermal coupling, thermal welding, a shrink sleeve, an O-ring or diametric seal, or an adhesive.

23. The duct coupler assembly of claim 22 , wherein the female duct coupler is coupled to the first duct segment and the male duct coupler is coupled to the second duct segment by press fitting, chemical welding, friction welding, thermal coupling, thermal welding, a shrink sleeve, an O-ring or diametric seal, or an adhesive.

24. The duct coupler assembly of claim 21 , wherein the female duct coupler further comprises an inner flange, the inner flange positioned within the female duct coupler body, the inner flange and female duct coupler body defining a seal groove therebetween, the seal groove being capable of receiving a male edge of the male duct coupler body.

25. The duct coupler assembly of claim 24 , further comprising a seal positioned within the seal groove.

26. The duct coupler assembly of claim 21 , wherein the first and second duct segments are duct.

27. The duct coupler assembly of claim 21 , wherein the female duct coupler and male duct coupler are separably coupleable.

28. The duct coupler assembly of claim 21 , wherein at least one of the duct couplers is formed integrally as an end of the first or second duct segments.

29. The duct coupler of claim 21 , wherein the bayonet slot has a helical path.