Plastic rock-bolt or dowel

Abstract

A rock-dowel has a dowel shank has a diameter of about 20-22 mm, and a threaded end at the head or proximal end of the dowel. Three groups of projecting mixing vanes are spaced along the shank. A first group of vanes at the tip project at least 2.5 mm and preferably no more than 4 mm from the shank. The second group of vanes which project from the shank by a lesser degree than the first group, are defined in a central portion of the shank spaced from the first group. The third group of vanes which project from the shank by a lesser degree than the second group, are defined adjacent the threaded portion of the shank spaced from the second group. In use when inserted into a pre-drilled hole containing a two-part encapsulating resin and spun, the rock-dowel can thoroughly mix the two part resin encapsulating resin and force the resin casings into the back of the pre-drilled hole. In particular, the vanes are designed to mix the resin in three stages, the first stage is at the tip of the dowel and these projections are the largest and designed to not only mix the two resins but create a very large “spin diameter” within the pre-drilled hole so that the spinning dowel is presenting to the resin capsule a much larger diameter enabling the two separate capsule casings to be broken. Also disclosed is a nut made from a plastics material defining a first, typically relatively wider, barrel portion and a second, typically relatively narrower, nut portion, the second portion defining a nut section for engagement with a socket, wherein an area of weakness is provided between the first and second portions such that the second portion breaks from the first portion when a particular torque value is applied to the nut, the predetermined torque value being less than the breaking torque of the dowel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

A specific embodiment of the present invention will now be described by way of example only, and with reference to the accompanying drawings, in which:—

FIG. 1 is an elevation of a threaded plastic rock dowel with mixing vanes, a washer plate and a nut showing sections of the dowel enlarged;

FIG. 1 a is an enlarged view of a portion of the shank of the rock dowel shown in FIG. 1;

FIG. 1 b in an elevation of one face “A” of the rock dowel of FIG. 1a.

FIG. 1 c in an elevation of the opposite face “B” of the rock dowel of FIG. 1a.

FIG. 2 is a section showing a typical rock-dowel, nut and plate assembled in a pre-drilled hole made in a coal strata;

FIG. 3 is an elevation of a nut with the holes and columns moulded into the junction of the barrel and hexagon sections to facilitate separation of the two sections;

FIG. 4 is an elevation of a nut showing recesses moulded into the flats of a hexagonal section to facilitate the disintegration of the hexagonal section after separation from the barrel section;

FIG. 5 is a plan view of the hexagon end of the nut showing the columns at the juncture of the barrel and hexagonal ends and the moulding slides to form the columns and holes;

FIG. 6 is a plan view of the diameter of a resin capsule showing two separated resin compartments; and

FIG. 7 is an elevation of a resin capsule also showing the two separated compartments

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring to the drawings, FIG. 1 shows one side of a fibre-reinforced plastic (FRP) rock-dowel 10. A view of the rock-dowel from the opposite side is substantially identical. The rock-dowel has a dowel shank 12 having a diameter of about 20-22 mm, defining a longitudinal axis 12a (refer to FIG. 1a) and a threaded end 14 at the head or proximal end of the dowel. Three groups 16, 18 and 20 of projecting mixing vanes are spaced along the shank 12. Also shown in FIG. 1 is a washer plate 11 and a nut 13.

The vanes 20, 22 of the first group 16 of projecting mixing vanes adjacent the threaded portion 14, project approximately 0.5 mm-1 mm out from the dowel shank 12, most preferably about 1 mm. Vanes 20, 22 extend out from opposed sides of the dowel shank separated by diametrically opposed flattened portions 24 of the shank, of which only one is shown. The vanes 20 extending from one side of the shank are offset from those 22 extending from the opposite side of the shank.

With reference to FIGS. 1a to 1c, it can be seen that the mixing vanes 22 on one side or face “A” of the shank are not perpendicular to the longitudinal axis but rather are part-helical/spiral having a left hand thread such that as the shank is rotated in a clockwise sense about its longitudinal axis, the vanes 22 tends to push material towards the head of the shank. The mixing vanes 20 on the opposite face B of the shank are also part-helical/spiral but have a right hand thread such that as the shank is rotated in a clockwise sense about its longitudinal axis, the vanes 20 tend to push material towards the tip of the shank. Thus in use, as is described below, the vanes counteract each other.

There are approximately ten vanes extending from either side of the shaft in the first group 16, however the specific number of vanes is not critical and may be varied.

There is a gap 12a on the shank where there are no vanes followed by the second group of vanes 18. The configuration of the second group is largely the same as that of the first group, with vanes 26 and 28 being offset relative to one another and separated by opposed flattened portions 24. The length of the gap 12a is not critical. The size of the vanes 26, 28 is greater than those of the first group, projecting from about 1.5 to 2 mm from the shank. While there are approximately ten vanes extending from either side of the shaft in the second group, the specific number of vanes is not critical and may be varied.

There is a gap 12b on the shank where there are no vanes followed by the third and final group of vanes 20 located at the distal or tip end of the shank. The configuration of the third group is largely the same as that of the first and second groups, with vanes 30 and 32 being offset relative to one another and separated by a flattened portions 24. The length of the gap 12b is again, not critical. The size of the vanes 30, 32 is greater than those of the second group, projecting from about 2.5 to 3 mm from the shank. The number of vanes in the third group should preferably be limited to between two and eight vanes on each side of the shank.

In all the groups 16, 18 and 20, the spacing between the vanes in each section can vary between 10 mm-30 mm, but is preferably about 20 mm.

In use, with reference to FIG. 2, a hole 4 is first drilled in the strata 5 where the rock-dowel 10 is to be installed, typically coal. Typically the hole 4 will have a diameter of approximately 28 mm however as coal is a friable material the diameter of the hole is unlikely to be consistent and the hole diameter may be as much as 32 mm depending on the size of the drill and the friability of the coal. A resin capsule 113 is then inserted in the drilled hole. The dowel is then partly inserted in the hole, spun and pushed further into the hole

FIGS. 6 and 7 show a typical resin capsule 113. These are typically approximately 24 mm in diameter having the two separate compartments 111 & 112. Compartment 111 is where the resin material is contained by casing 109 and consists of approximately 85% of the volume. Compartment 112 is where the catalyst (approximately 15% of volume) is contained in casing 110. When the catalyst in compartment 112 is mixed with the resin in compartment 111, an exothermic reaction occurs, causing the resin to harden.

During the dowel 2 spinning operation, both capsule compartments 111 and 112 must be broken open and fully mixed together.

The cross-sectional area of the resin compartment 111 is approximately 445 mm². The cross-sectional area of the smaller catalyst compartment 112 is only approximately 65 mm². With previous rock-dowels of the prior art, often a dowel will pierce the larger compartment 111 and miss the smaller catalyst compartment 112 partly or wholly, allowing the compartment 112 or casings 109 and 110 to wrap around the spinning dowel 2, failing to mix the resins 111 and 112 and causing “gloving.

In use the dowel 12 is inserted into the hole to pierce the capsules and is spun to mix the resin and catalyst.

With the rock-dowel 10 embodying the present invention, the vanes project out from the shank creating a larger effective spin diameter. In particular, the mixing vanes 30, 32 project out from the dowel shank by approximately 2.5 mm-3 mm creating a spin diameter of up to 6 mm larger than the diameter of the dowel shank 12. As the normal shank 12 diameter is 20 mm-22 mm the spin diameter is up to 26 mm-28 mm in a predrilled hole 4 of approximately 28 mm-32 mm depending on the drill diameter and strata condition of the coal strata. This improves the mixing and increases the chances of properly piercing and mixing both compartments.

While less critical than the end vanes 30 and 32, the vanes in the groups 18 and 20 also project from the dowel shank 12 and create a vigorous agitating and mixing environment.

As discussed above because the part-helical mixing vanes on opposite sides of the shank are opposite in sense, being left and right handed the vanes agitate the two part resin driving it back and forth in turn, without forcing the resin or the casings either into or out of the hole.

The annulus gap 4a, that is, the difference between the effective diameter of the spinning dowel 10 and the pre-drilled hole 4 diameter is dramatically reduced whilst still allowing room for the mixed but as yet unhardened resin 4a to travel up the dowel shank 12 towards the dowel head as the dowel is thrust deeper into the predrilled hole 4 displacing the mixed resin 4a, and without significantly increasing the volume of the shank 12. Increasing the volume of the shank would not only leave less room for the resin mixture to move but also increase the materials used to make the shank and consequently its cost.

To show how the spin diameter affects the performance of the encapsulation process, by mixing the resin 4a and preventing the ruptured resin capsule casings 109 and 110 from wrapping around the spinning dowel 2, the effect of larger spin diameters can be expressed in area values.

For example, a 28 mm diameter drilled hole 4 has a diameter area of 616 mm², a 20 mm diameter dowel has a diameter area of 314 mm or approximately 51% compared to the hole, this means that the “free area” not affected by the spinning dowel is 302 mm².

The same 20 mm diameter dowel with a 3 mm projection on both sides has a spin diameter of 26 mm and a spin diameter area of 513 mm with a “free area” not affected by the spinning dowel 10 of only 85 mm², a reduction of over 70% without enlarging the dowel shank diameter or increasing the effective dowel cost. The unaffected “free area” is reduced to approximately 14% of the diameter area of the drilled hole 4

The spin diameter area of the dowel 2 is the most critical element to achieve satisfactory encapsulation and should range between 60%-85% of the drilled hole diameter area. These percentages are not achievable without the mixing vanes 30, 32, as the diameter of the spinning dowel 2 becomes too large to allow the mixed resin 4a to transfer backwards towards the hole opening and encapsulate the dowel.

The spin diameter of the vanes increases the effective spin diameter of the dowel shank by between 15 and 50%.

By narrowing the annular gap 4a both resin casings 109 and 110 are broken and then thrust down into the back of the hole 4 by the spinning dowel 10 so that the casings 109 and 110 cannot wrap around the spinning dowel shank 12.

The dowel 10 shown in FIG. 1 is preferably manufactured in a one piece and in one single process. This is desirable for strength and cost reasons.

In a variant, a smaller shank diameter could be used but with larger vanes. For example with a shank diameter of 18 mm, the vanes 16 could project out from the dowel shank by 1.5 mm-2 mm, the vanes 18 could project by 2.5 mm-3 mm and the vanes 20 by 3.5 mm-4 mm.

During the spinning operation to assist in the migration of the mixed but as yet unhardened resin 4a up towards the dowel head the dowel shank 2a should be constrained in diameter and could even be tapered or stepped approximately 2 mm so that it has a smaller diameter at the dowel shank tip. This reduces back pressure in the hole 4 and on the unmixed resin 4a which, if allowed, can migrate into the fissures of the fractured coal material and cause a loss in bonding to the coal strata.

FIG. 3 shows the cooperating nut 13 in more detail. It includes a circular generally annular barrel section 120 connected to a co-axial hollow hexagonal section 122 by a recessed annular weakened portion 123. The hollow hexagonal section may or may not be internally threaded. The barrel section 120 has an internal thread 124. A breakout cap 126 that allows the dowel 10 to be spun during the spinning and mixing stage separates the interior of the barrel section 120 from the hexagonal section 122. This cap 126 will break out at a set torque level significantly less than the torque level required to shear the weakened portion 123 and separate the hexagon 122 and barrel 120. Also shown are apertures 128 in the weakened portion 123 and recesses 130 (refer to FIG. 4) which combine to allow the hexagon section 122 to separate from the barrel section 120 at the required torque value.

The position of the breakout cap 126 as shown in FIGS. 3 and 4 is close to the junction 123 of the hexagon section 122 and the barrel section 120. This is preferable in that when these two sections part and the nut 13 is in the final position, the amount of projection of the threaded end 14 of the dowel will be as small as possible.

The lesser projection of the threaded portion 14 is particularly significant when the installation operator has used what is termed a “thrust” installation. In such an operation, immediately on completion of the dowel spinning stage, the dowel 10 is thrust hard against the washer plate 3 and strata surface 5 and held whilst the resin in the gap 4a is hardening. The nut 13 when finally tightened will only advance several threads and not project any further than approximately 25 mm out from the end of the barrel section 120 or project no more than the original position of the hexagon section 122 before it separates from the barrel 120.

The position of the cap 126 in the nut 13 may also be critical for other reasons. The size and configuration of the hexagonal section 122 is dictated in coal tunnels by the size of the steel nut used in the other non cuttable areas as the operators refuse to constantly keep changing the drill chuck socket to suit plastic nuts. Traditionally with both steel and plastic nuts the position of the cap has been at the very end of the hexagonal section 112 or at the top of the nut 13. The hexagonal size restriction has created a problem for plastic nuts in that to obtain a high cap breakout value the whole or part of the top of the hexagon breaks away with the cap yielding enormous variations and unreliable cap breakout values. By placing the cap in between the hexagon 122 and barrel section 120 as shown in FIGS. 3 and 4 the cap can be thickened for higher breakout values without affecting the hexagonal section 122.

FIG. 4 shows another view of the nut 13 showing recesses moulded into some of the flats of the hexagon section 122 to facilitate the disintegration or collapsing of the hexagon section 122 after it separates from the barrel section 120.

FIG. 5 shows a plan view of the barrel section 120, the apertures 128 and the columns 130. Also shown is the method of forming the holes or apertures 128 and the columns 130 by horizontal slides 8 with projections 7 that form the apertures or holes. The apertures 128 do not have to actually penetrate the full section but preferably do penetrate enough to significantly weaken the section so it cannot add significantly to the torque value. The columns 130 may take any convenient configuration but should be approximately equal in shear strength for reliability.

The size of the apertures 128 will vary with the required torque value required which will vary with the diameter of the rock-dowel 10 and the ultimate strength of the dowel shank 12.

A significant feature and advantage of this reinforcing system is that if the encapsulation is faulty or insufficient the hexagon and barrel section will not separate. Instead the whole head of the dowel will shear off as the torque value of the dowel will be exceeded before the torque value of the separating barrel 120 and hexagon 122 sections is reached. The operators are thus instantly alerted to the dowel head and shank failure and must install another replacement dowel with a longer resin capsule to complete the reinforcement.

In this way the reinforcing system is fail safe in that operators no longer have to be too careful and tentative when tightening the nut and are confident that the dowel 10 is undamaged and a minimum force of approximately 2 tonnes-4 tonnes load is applied to the strata 5 surface. This system speeds up the installation operation and removes the remedial repair work required when the reinforcement system is not installed correctly and the strata 5 begins to collapses

In FIG. 2 part of the dowel 10 is shown inserted into the pre-drilled hole 4 in the coal strata 5, the nut 13 goes through two separate stages. The first stage is the spinning operation. The second stage is cap 6 breakout and torque shear stage when the hexagon section 1b shears off.

The nut 1 in FIG. 2 is shown in between the first and the second stage of installation after the nut cap 6 (not shown) has been broken out and extended down the threaded section the dowel 2 is locked in by the encapsulation and hardened resin 4a.

The second stage of installation is the further tightening of the nut 1 down onto the plate 3 and strata surface 5. The section with holes or apertures 1a allows the hexagon shaped back of the nut 1b to shear off at a prescribed torque value. Sometimes there can be a steel or plastic mesh between the strata surface and the washer, this is to hold back coal from falling out from areas between the spacings of the dowel installation.

It will be appreciated by persons skilled in the art that numerous variations and/or modifications may be made to the invention as shown in the specific embodiments without departing from the spirit or scope of the invention as broadly described. The present embodiments are, therefore, to be considered in all aspects as illustrative and not restrictive

Claims

1. The plastic rock dowel for use in reinforcing strata or the like having a generally cylindrical shank, the shank defining a tip portion and wherein a first group of spaced apart mixing vanes which project at least 1.5 mm and preferably no more than 5 mm from the shank are defined at or adjacent to a tip portion of the shank.

2. The plastic rock dowel as claimed in claim 1 wherein a head portion of the shank has a larger diameter than the tip portion, excluding the vanes.

3. The plastic rock dowel as claimed in claim 1 wherein the shank is tapered.

4. The plastic rock dowel as claimed in claim 1 wherein the shank includes one or more stepped changes in diameter.

5. The plastic rock dowel as claimed in claim 1 wherein the first group of vanes project from diametrically opposed sides of the shank, are offset relative to one another along the longitudinal axis of the shank and are separated by diametrically opposed longitudinally extending portions of the shank which do not define projections.

6. The plastic rock dowel as claimed in claim 5 wherein the longitudinally extending portions of the shank are generally planar.

7. The plastic rock dowel as claimed in claim 1 wherein a second group of vanes which project from the shank by a lesser degree than the first group, are defined in a central portion of the shank spaced from the first group.

8. The plastic rock dowel as claimed in claim 7 wherein the second group of vanes project from the shank by at least 1.5 mm and preferably no more than 2 mm.

9. The plastic rock dowel as claimed in claim 7 wherein a third group of vanes which project from the shank by a lesser degree than the second group, are defined adjacent a head portion of the shank spaced from the second group.

10. The plastic rock dowel as claimed in claim 9 wherein the third group of vanes project at least 0.5 mm from the shank and preferably no more than 1 mm.

11. The plastic rock dowel as claimed in claim 5 wherein the vanes on one of the diametrically opposed sides of the shank are part-helical, the vanes on one side having left hand thread and the vanes on the opposite side having a right hand thread.

12. The plastic rock dowel as claimed in claim 1 wherein the end of the shank which is distal from the tip is externally threaded.

13. The plastic rock dowel as claimed in claim 1 wherein the dowel in manufactured in one piece from a fibre reinforced plastic and the diameter of the shank is from 18 to 22 mm.

14. The plastic rock dowel as claimed in claim 1 wherein relative to a hole having a diameter into which the dowel is to be inserted, the spin diameter area of the first group of vanes generated by revolving the shank through 360° about its longitudinal axis is from 60 to 85% of the diameter area of the hole.

15. The plastic rock dowel as claimed in claim 14 wherein the diameter of the hole is about 28 mm.

16. The plastic rock dowel as claimed in claim 2 wherein there are from two to eight vanes in the first group disposed either side of the diametrically opposed longitudinally extending portions of the shank.

17. A combination of a rock dowel having a generally cylindrical shank, the shank defining a tip portion and wherein a first group of spaced apart mixing vanes which project at least 1.5 mm and preferably no more than 5 mm from the shank are defined at or adjacent to a tip portion of the shank; and a nut made from a plastics material defining a first, typically relatively wider, barrel portion and a second, typically relatively narrower, nut portion, the second portion defining a nut section for engagement with a socket, wherein an area of weakness is provided between the first and second portions such that the second portion breaks from the first portion when a particular torque value is applied to the nut.

18. The combination as claimed in claim 17 wherein the nut comprises a fibre reinforced plastics material.

19. The combination as claimed in claim 17 wherein the particular torque value is set to be less than the breaking torque of the rock-dowel so that the nut portion shears off during installation in preference to the dowel, thus preventing damage to the dowel.

20. The combination as claimed in claim 17 wherein the nut includes a frangible cap separating the interior of the barrel portion from the nut section.