1. Field of the Invention
The present invention relates to a mine roof bolt anchored in a bore hole by resin bonding, and more particularly to a mine roof bolt bearing a polymer coating layer between a steel bolt and the resin bonding, that yields under loading.
2. Description of Related Art
The roof/ribs of a mine conventionally are supported by tensioning the roof with 4 to 6 foot long steel bolts inserted into bore holes drilled in the mine roof that reinforces the unsupported rock formation above the mine roof. The end of the mine roof bolt may be anchored mechanically to the rock formation by engagement of an expansion assembly on the end of the mine roof bolt with the rock formation. Alternatively, the mine roof bolt may be adhesively bonded to the rock formation with a resin bonding material inserted into the bore hole. A combination of mechanical anchoring and resin bonding can also be employed by using both an expansion assembly and resin bonding material.
A mechanically anchored mine roof bolt typically includes an expansion assembly threaded onto one end of the bolt shaft and a drive head for rotating the bolt. A mine roof plate is positioned between the drive head and the mine roof surface. The expansion assembly generally includes a multi-prong shell supported by a threaded ring and a plug threaded onto the end of the bolt. When the prongs of the shell engage with rock surrounding a bore hole, and the bolt is rotated about its longitudinal axis, the plug threads downwardly on the shaft to expand the shell into tight engagement with the rock thereby placing the bolt in tension between the expansion assembly and the mine roof surface.
When resin bonding material is used, it penetrates the surrounding rock formation to unite the rock strata and to firmly hold the roof bolt within the bore hole. Resin is typically inserted into the mine roof bore hole in the form of a two component plastic cartridge having one component containing a curable resin composition and another component containing a curing agent (catalyst). The two component resin cartridge is inserted into the blind end of the bore hole and the mine roof bolt is inserted into the bore hole such that the end of the mine roof bolt ruptures the two component resin cartridge. Upon rotation of the mine roof bolt about its longitudinal axis, the compartments within the resin cartridge are shredded and the components are mixed. The resin mixture fills the annular area between the bore hole wall and the shaft of the mine roof bolt. The mixed resin cures and binds the mine roof bolt to the surrounding rock.
With certain mining conditions, particularly those found in hard rock mining, the rock formation in the ribs and above the mine roof are susceptible to movement or rock burst as a result of mine-induced seismicity, the excavation of perimeter rock, minor earthquakes, etc. Under dynamic loading caused by rock bursts, the typical mine roof bolts described above are vulnerable to failure. Various mine roof bolts have been designed in an effort to better withstand rock bursts. In particular, mine roof bolts have been designed to yield allowing the bolt to absorb some of the dynamic loading caused by a rock burst. One such design employs a conical-shaped portion at the far end of the bolt, which is designed to pull through the resin or grout in response to excessive forces applied to the bolt. A further design, as disclosed in U.S. Pat. No. 6,984,091, utilizes a bolt having a widened portion of the bolt shaft that is pulled through a longitudinal bore of an anchor member secured within the bore'hole.
In one embodiment, a mine roof bolt includes an elongated rod and a polymer coating layer. The elongated rod has a first end and a second end. A protruding portion extends radially outward from the elongated rod. The polymer coating layer covers at least a portion of the elongated rod between the first and second ends. The elongated rod is movable relative to the polymer coating layer in an axial direction. The elongated rod has a first position where the elongated rod has a predetermined axial position relative to the polymer coating layer and a second position where the elongated rod has a displaced axial position relative to the first position.
The polymer coating layer may comprise a polymeric material and the polymer coating layer may cover the protruding portion of the elongated rod. The protruding portion may be positioned adjacent to the second end of the elongated rod. The polymer coating layer may have a first thickness at the protruding portion and a second thickness at a remaining portion of the elongated rod. The first thickness may be smaller than the second thickness. The protruding portion may be integral with the elongated rod. A transition between the protruding portion and the elongated rod may include a radiused portion. The first end of the elongated rod may include a threaded portion and a drive nut may be positioned on the threaded portion. The first end of the elongated rod may include a drive head and the drive head may be integral with the elongated rod.
In a further embodiment, a method of supporting a mine roof includes inserting a frangible resin cartridge into a bore hole formed in the mine roof, and positioning a mine roof bolt in the bore hole. The mine roof bolt includes an elongated rod having a first end and a second end. A protruding portion extends radially outward from the elongated rod, and a polymer coating layer covers at least a portion of the elongated rod between the first and second ends. The protruding portion includes an outer threaded surface. The method further includes rupturing the resin cartridge, rotating the mine roof bolt about a longitudinal axis of the elongated rod in a first direction to mix contents of the resin cartridge, and rotating the mine roof bolt about the longitudinal axis in a second direction to tension the mine roof bolt.
The mine roof bolt may be rotated in the first and second directions via a drive head. The elongated rod may be axially displaced relative to the polymer coating layer during rotation of the mine roof bolt in the second direction. The elongated rod may rotate relative to the polymer coating layer during rotation of the mine roof bolt in the first and second directions. The elongated rod may be restricted from axial movement relative to the polymer coating layer during rotation of the mine roof bolt in the first direction via engagement of the protruding portion with the polymer coating layer. The outer threaded surface of the protruding portion may engage the polymer coating layer to cause the axial displacement of the elongated rod relative to the polymer coating layer. The drive head may be formed integrally with the elongated rod and the polymer coating layer may be anchored within the bore hole after mixing the contents of the resin cartridge and upon curing of the contents of the resin cartridge.
The present invention will now be described with reference to the accompanying figures. For purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom,” and derivatives thereof shall relate to the invention as it is oriented in the drawing figures. However, it is to be understood that the invention may assume various alternative variations and step sequences, except where expressly specified to the contrary. It is to be understood that the specific apparatus illustrated in the attached figures and described in the following specification is simply an exemplary embodiment of the present invention. Hence, specific dimensions and other physical characteristics related to the embodiments disclosed herein are not to be considered as limiting.
Referring to
The mine roof bolt 10 includes a polymer coating layer 50 having a plurality of tapered segments 52. The polymer coating layer 50 extends from an intermediate position of the elongated rod 15 to the insertion end 25. The mine roof bolt 10 may include a resin retaining ring 45 disposed over the elongated rod 15. The elongated rod 15 may have a length of 6 to 13 feet and the threaded drive end 20 may be 3 to 6 inches. Further, the polymer coating layer 50 may have a length of 6 feet and the protruding portion 28 of the insertion end 25 may have a length of 1.25 inches. Other lengths of the elongated rod 15, drive end 20, protruding portion 28, and polymer coating layer 50, however, may be selected depending on roof anchoring needs. The elongated rod 15 may be a smooth rod made from 0.680 inch steel round bar and the protruding portion 28 may have a diameter of 0.800 to 0.850 inches, although other suitable size diameters may be used for the elongated rod 15 and protruding portion 28. The polymer coating layer 50 may be produced from plastic, such as nylon, polycarbonate, or polyethylene terephthalate (PET), although other suitable material may be used provided the material functions during impact loading as described below. In a particular embodiment, the polymer coating layer 50 is 13% glass-filled nylon, although other percentages of glass-filled nylon may be used.
As discussed in more detail below, the elongated rod 15 is movable relative to the polymer coating layer 50 in an axial direction, i.e., along a longitudinal axis of the elongated rod 15 extending between the drive end 20 and the insertion end 25. The elongated rod 15 has a first position (such as that shown in
The mine roof bolt 10 may be produced by coating the elongated rod 15 with a flowable polymer so that the coating has a thickness of, for example, about at least 1 mm. The polymer is allowed to solidify on the elongated rod 15 and texturing is applied to the exterior of the polymer to form spiral threads 54 and ridges 58. The coating step may be performed by dip coating, injection molding, and/or hot forging of the polymer resulting in an outer layer of a low density hard coating of the polymer coating layer 50 on an inner portion of higher density material (e.g., steel) of the elongated rod 15. Suitable polymer and methods of applying polymer coating layers 50 are described in U.S. Pat. No. 7,296,950 to Stankus et al, incorporated herein by reference in its entirety.
Referring to
Referring to
Referring to
With respect to the mine roof bolts 10, 10′ discussed above, the polymer coating layer 50 serves several functions during installation and after the bolt 10, 10′ is installed in the mine roof 73. As the bolt 10, 10′ is rotated about its longitudinal axis, the spiral threads 54 on the polymer coating layer 50 urge resin 82 upwardly toward the blind end 89 of the bore hole 85. Retention of resin 82 at the blind end 89 of the bore hole 85 is desired to ensure good bonding between the mine roof bolts 10, 10′ and the surrounding rock and to concentrate the anchoring function at the insertion end 25 of the bolt 10, 10′. Sufficient resin 82 is required in the annulus between the mine roof bolt 10, 10′ and the bore hole wall to completely fill the annulus and allow for some of the resin 82 to fill cracks and crevices in the rock to enhance the interlock between the rock and the mine roof bolt 10, 10′. In addition, bolts that are anchored via resin bonding create a “point anchor” that permits tensioning of the bolt between the resin point anchor and the mine roof surface. Retention of the resin 82 at the upper end of the bolt 10, 10′ allows a point anchor system that is tensionable. The polymer coating layer 50 also serves to mix the resin 82. The spiral threads 54 and the ridges 58 provide mixing surfaces to enhance mixing of the curable resin 82. The segmented arrangement of the polymer coating layer 50 also provides surface disruptions that enhance mixing and improve anchorage. To improve the centering of the bolt with the polymer coating layer 50, small projections (not shown) of 1-2 mm every 75-100 mm of longitudinal length and at 90 degree arc spacing may be formed on the outer surface of the polymer coating layer 50. These projections also aid in the rupturing of the resin cartridge film and mixing of the two resin components.
During impact or dynamic loading, particularly during an impact load of 8-10 tons, the elongated rod 15 pulls through and is displaced relative to the polymer coating layer 50, which remains anchored within the bore hole 85 via the resin 82. As shown more clearly in
Accordingly, the mine roof bolts 10, 10′ yield under an impact load to absorb energy and reduce the likelihood of an immediate failure of the mine roof bolts 10, 10′. The movement of the elongated rod 15 within the polymer coating layer 50 also provides an indication of an unstable roof condition so that workers in the area may reinforce the roof or evacuate. Typically, after experiencing a shift in rock strata or other seismic event, the roof in the area of the shift will be re-bolted or reinforced in some other manner. The dimensions of the protruding portion 28 of the insertion end 25 may be selected to control the amount of yielding or displacement of the elongated rod 15 within the polymer coating layer 50. Although the mine roof bolts 10, 10′ are shown to be centered within the bore hole 85 and the protruding portion 28 is concentric with the elongated body 15, the bolts 10, 10′ may be positioned off center in the bore hole 85 and the protruding portion 28 may be non-concentric with elongated rod 15. The bolts 10, 10′ generally experience consistent displacement of the elongated rod 15 within the polymer coating layer 50 upon initial and subsequent dynamic loads. Further, the mine roof bolts 10, 10′ also typically have low bolt stretch or plastic deformation relative to the movement of the anchorage, i.e., the movement of the elongated rod 15 within the polymer coating layer 50. For instance, upon second and third cycles of dynamic loading, the bolts 10, 10′ generally have consistent anchorage movement while having relatively low plastic deformation of the bolts 10, 10′.
A laboratory pull was conducted to determine the performance of the mine roof bolts 10, 10′ of the present invention. The test was designed to determine the degree of displacement (length) that a bolt produced according to the present invention will exhibit upon receiving a load. The test was performed with a 0.680 inch smooth bar as the elongated rod 15 with a 0.850 inch diameter protruding portion 28. The length of the bolt 10 tested was 26.125 inches in length and the protruding portion 28 was 1.25 inches in length. The polymer coating layer 50 was a polycarbonate coating with a mold release agent applied to the elongated rod 15. The bolt 10 was installed in a 35 mm diameter steel tube with an outer diameter of 1.875 inches. Original embodiment length was 15 inches in the tube with 18 inches having the polymer coating layer 50. As load was added to the free end of the bolt 10, the displacement of the bolt 10 was measured. The bolt 10 was displaced approximately 20 mm at a load of 11 tons and approximately 40 mm at a load of 16 tons. The final load was 19.5 tons and the final length of the bolt 10 was 27.125 inches. The anchorage movement was approximately 3.750 inches. The bolt 10 generally experienced consistent anchorage movement.
While several embodiments of the point anchor yielding bolt were described in the foregoing detailed description, those skilled in the art may make modifications and alterations to these embodiments without departing from the scope and spirit of the invention. Accordingly, the foregoing description is intended to be illustrative rather than restrictive.
This application claims the benefit of U.S. Provisional Application No. 61/238,849, filed Sep. 1, 2009, the entire content of which is hereby incorporated by reference.
Number | Name | Date | Kind |
---|---|---|---|
3899893 | Banerjee et al. | Aug 1975 | A |
3940941 | Libert et al. | Mar 1976 | A |
4659258 | Scott | Apr 1987 | A |
5152649 | Popp | Oct 1992 | A |
5249898 | Stepanski et al. | Oct 1993 | A |
5344268 | Fischer | Sep 1994 | A |
6984091 | Maltby | Jan 2006 | B2 |
7296950 | Stankus et al. | Nov 2007 | B1 |
20090136302 | Fox | May 2009 | A1 |
Number | Date | Country |
---|---|---|
0251887 | Jan 1988 | EP |
2006105557 | Oct 2006 | WO |
2010078639 | Jul 2010 | WO |
Number | Date | Country | |
---|---|---|---|
20110052332 A1 | Mar 2011 | US |
Number | Date | Country | |
---|---|---|---|
61238849 | Sep 2009 | US |