Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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FRICTION STABILIZER WITH TABS
Cave-ins are a constant threat associated with underground mining
operations. It is difficult to predict when and where a cave-in will occur.
Typically,
workers are provided with little or no warning prior to a cave-in, and thus
they have a
minimal amount of time to react to a cave-in. Indeed, mine walls or ceilings
that
appear fine upon visual inspection may have significant fractures just below
their
surfaces, making them structurally weak and prone to collapse. Cave-ins are
very
destructive and may result in miners becoming trapped and/or injured.
Additionally,
equipment and niachinery may be damaged or destroyed.
Friction type stabilizers have been used in mining operations to
stabilize walls and ceilings of the mine. Such stabilizers are pounded into
bores
drilled in mine walls and ceilings. The stabilizers fonn a friction fit with
the drilled
bore. But, these stabilizers may slide out of the drilled bores when the rock
wall or
ceiling shifts/moves, and in such situations the stabilizers are unable to
prevent a rnine
wall or ceiling cave-in.
Therefore, it would be desirable to provide a new and improved
stabilizer that decreases the likelihood of a cave-in. It would also be
desirable if the
stabilizer was compatible with existing mining equipment and inexpensive to
fabricate.
The friction stabilizer with tabs according to this invention is used to
secure the walls and ceilings of mines to thus prevent a cave-in from
occurring. The
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friction stabilizer with tabs comprises a hollow body, preferably tubular. The
tubular
body comprises ati impact end, an insertion end, a first portion and a second
portion.
The second portion has a notch and is tapered.
The tubular body has an interior and an exterior surface, and tabs are
connected to and extend from the tubular body. The tabs extend in a direction
leading
away from the insertion end of the tubular body and in a direction leading
towards the
impact end of the tubular body. The tabs each make an acute angle with the
exterior
surface of the tubular body. The tabs can be rectangular shaped and there can
be three
such tabs extending from the exterior surface of the tubular body. Each
rectangular
shaped tab further comprises parallel tab side edges and a tab free edge
connecting
between the tab side edges.
In other embodiments, the tabs may be triangular shaped tabs, curved
shaped tabs, polygonal shaped tabs, U-shaped tabs, tabs having both curved
portions
and linear portions, semi-circular shaped tabs, hook shaped tabs, parabolic
shaped
tabs, and combinations of the above. Also, the tabs can be of any shape that
inhibits
the withdrawal of the friction stabilizer with tabs from the drilled bore in a
mine. The
above-described tabs are punched into the sheet from which the tubular body is
formed by a punching machine, thus they are joined to the tubular body at
bends.
The tubular body further comprises a first gap space wall and a second
gap space wall spaced apart from one another by a tube gap space. The tube gap
space
is used for allowing the tubular body to be compressed radially inward when
the
tubular body is driven into a drilled bore in a mine having, the drilled bore
having a
diameter less than the outer diameter of the tubular body.
The friction stabilizer further comprises a weld ring having a weld ring gap
space, and
the weld ring is joined to the tubular body such that the weld ring gap space
and tube
gap space are aligned. The weld ring is joined to the exterior surface of the
first
portion of the tubular body at the impact end of the tubular body by, for
example, a
weld. The weld ring gap space is used for allowing the weld ring to be
compressed
radially inward. 'The weld ring can have a rectangular cross section or a
circular cross
section.
In another embodiment, a friction stabilizer for installation in a
structural body is provided. The friction stabilizer has a tubular body
comprising a
first portion a bent portion and a second portion with and the bent portion
joining the
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first portion and second portion. The first portion has an extendable tab and
a joining
portion joins the extendable tab and the tubular body such that the extendable
tab is
proximal the bent portion. The friction stabilizer also has a tube gap space
and an
opening diametrically opposite the tube gap space, such that the extendable
tab
extends from the joining portion into the opening. The extendable tab is
diametrically
opposite the tube gap space.
The tubular body is movable from an uncompressed position to a
compressed position, such that when in the tubular body is in the uncompressed
position the extendable tab is partly positioned in the opening. The tubular
body also
has an exterior surface and when in the uncompressed position the extendable
tab is
elevated a minimal amount relative to the surrounding exterior surface of the
tubular
body. The extendable tab extends outward from the tubular body when the
tubular
body is in the conipressed position, for example when hammered into a drilled
bore.
The friction stabilizer includes an insertion end and an opposed impact
end with a weld ring having a weld ring gap space joined to the impact end,
such that
the weld ring gap space is diametrically opposite the tube gap space. The
extendable
tab extends in a direction toward the impact end and away from the insertion
end.
The friction stabilizer can have another extendable tab proximal the
extendable tab
and positioned diametrically opposite the tube gap space. The extendable tab
can be
rectangular or have any suitable geometric shape.
Either embodiment of the friction stabilizer is made by similar
processes. The process begins by providing a coil of metal and unrolling the
coil of
metal into a strip, followed by pressing the shape of the tab or extendable
tab to be
formed into the strip of metal. The strip is moved through cold rolling dies,
and in
one embodiment the strip is rolled into a tubular body having a tube gap space
such
that the tabs extend from the tubular body. In the other embodiment the strip
is rolled
into a tubular body having a tube gap space and an exterior surface such that
the
extendable tab is elevated a minimal amount relative to the exterior surface
and is
diametrically opposite the tube gap space. The method also includes providing
a weld
ring having a weld ring gap space and welding the weld ring to the impact end
of the
tubular body.
To use the friction stabilizer with tabs, a drilled bore is made in the
wall or ceiling of the mine. The wall is sufficiently solid and of sufficient
thickness to
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accommodate a bore of sufficient length, and the drilled bore has a diameter
slightly
less than the diameter of the tubular body. A support plate having an opening
is
provided, the operiing being sized such that the tubular body can pass through
the
opening. The opening in the plate is aligned with the drilled bore. The
tapered end of
the tubular body is aligned with and inserted through the opening in the plate
and into
the drilled bore so that the taper of the tubular body is received in the
drilled bore.
Then a pneumatic or hydraulic hammer or some other means for
hammering is used for pounding or driving the stabilizer with tabs into the
drilled
bore. As the stabilizer with tabs is driven into the drilled bore the tabs
move or flex
inwardly towards the exterior surface of the tubular body. This allows the
friction
stabilizer with tabs to be hammered into the drilled bore without the tabs
impeding
movement. During the pounding process the plate becomes trapped between the
weld
ring and the surrounding ceiling or wall of the mine, as the case may be.
Additionally, the tubular body compresses and the gap space distance decreases
as the
friction stabilizer is driven into the drilled bore. Then, if loading force is
applied to
remove the tubular body with tabs,.the tabs immediately dig into the
surrounding wall
which surrounds the drilled bore, making the removal of the tubular body
significantly more difficult. Such loading force may come from the plate that
is
providing support. Thus, if the ceiling or wall begins to cave-in, the tabs
will keep
digging into the surrounding wall, and the friction stabilizer having tabs
continues to
work against a cave-in. This digging-in action could stop a cave-in in
progress or
limit the severity of a cave-in. Additionally, the digging-in action could
provide
miners with extra time to get out of harms way, or provide inspectors with
time so
that they can conduct an on site inspection.
The use of the friction stabilizer having the extendable tab is the same
the friction stabilizer is hammered into a drilled bore. However, as the
friction
stabilizer is hamniered into the drilled bore, it moves from an uncompressed
position
to a compressed position. As this occurs, the extendable tab moves away from
the
exterior surface of the tubular body and extends outward and into the
surrounding
drilled bore. The extendable tab is positioned deep in the drilled bore after
hammering, which advantageously provides the friction stabilizer with
increased axial
load carrying capacity.
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Brief Description Of The Figures
FIG. 1 is an elevational view of the friction stabilizer having tabs.
FIG. 2 is a side elevational view of the friction stabilizer having tabs.
FIG. 3 is a bottom plan view of the friction stabilizer having tabs.
FIG. 4 is a top plan view of the friction stabilizer having tabs.
FIG. 5 is a sectiorial view of the friction stabilizer having tabs taken along
cut line 5-
5.
FIG. 6 is a sectior-al view of the friction stabilizer having tabs taken along
cut line 6-
6.
FIG. 7 is a top plan view of the strip of steel used to manufacture the
friction stabilizer
having tabs.
FIG. 8 shows a bottom plan view of a second embodiment of the friction
stabilizer
with rectangular tabs according to a second embodiment of the invention.
FIG. 9 shows a side elevational view of the second embodiment of the friction
stabilizer with rectangular tabs.
FIG. 10 shows a top plan view of the second embodiment of the friction
stabilizer
with rectangular tabs.
FIG. 11 shows a sectional view of the second embodiment of the friction
stabilizer
with rectangular tabs taken along cut line 11-11 in FIG. 10.
FIG. 12 shows a sectional view of the second embodiment of the friction
stabilizer
with rectangular tabs taken along cut line 12-12 in FIG. 8.
FIG. 13 shows a bottom plan view of a third embodiment of the friction
stabilizer
with tabs.
FIG. 14 shows a side elevational view of the third embodiment of the friction
stabilizer with tabs.
FIG. 15 shows a'top plan view of the third embodiment of the friction
stabilizer with
tabs.
FIG. 16 shows a sectional view of a third embodiment of the friction
stabilizer with.
tabs taken along cut line 16-16 in FIG. 15. 30 FIG. 17 shows a sectional view
of the third embodiment of the friction stabilizer with
tabs taken along cut line 17-17 in FIG. 13.
FIG. 18 shows a bottom plan view of a fourth embodiment of the friction
stabilizer
with tabs.
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FIG. 19 shows a side elevational view of the fourth embodiment of the friction
stabilizer with tabs.
FIG. 20 shows a top plan view of the fourth embodiment of the friction
stabilizer with
tabs.
FIG. 21 shows a sectional view of the fourth embodiment of the friction
stabilizer
with tabs taken along cut line 21-21 in FIG. 20.
FIG. 22 shows a sectional view of the fourth embodiment of the friction
stabilizer
with tabs taken along cut line 22-22 in FIG. 18.
FIG. 23 shows a bottom plan view of a fifth embodiment of the friction
stabilizer with
tabs.
FIG. 24 shows a side elevational view of the fifth embodiment of the friction
stabilizer with tabs.
FIG. 25 shows a top plan view of the fifth embodiment of the friction
stabilizer with
tabs.
FIG. 26 shows a cross sectional view of the fifth embodiment of the friction
stabilizer
with tabs taken along cut line 26-26 in FIG. 25.
FIG. 27 shows a cross sectional view of the fifth embodiment of the friction
stabilizer
with tabs taken along cut line 27-27 in FIG. 23.
FIG. 27A shows a top plan view of a of a sixth embodiment of the friction
stabilizer
with tabs having a plurality of differently shaped tabs.
FIG. 28 is a diagrammatic view of the manufacturing process used for
manufacturing
the friction stabilizer with tabs.
FIG. 29 is a top plan view of the weld ring having a circular shaped cross
section.
FIG. 30 is a sectional view taken along cut line 30-30 in FIG. 29 of the weld
ring
having a circular shaped cross section.
FIG. 30a is a view, partly in section, of the circular weld ring and tubular
body joined
together with a weld.
FIG. 31 is a top plan view of the weld ring having a rectangular shaped cross
section.
FIG. 32 is a sectional view taken along cut line 32-32 in FIG. 31 of the weld
ring
having a rectangular shaped cross section.
FIG. 32a is a view, partly in section, of the rectangular weld ring and
tubular body
joined together with a weld.
FIG. 33 is a top plan view of the planar plate.
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FIG. 34 is a sectional view of the planar plate taken along cut line 34-34 in
FIG. 33.
FIG. 35 is a top plan view of the domed plate.
FIG. 36 is a sectional view of the domed plate taken along cut line 36-36 in
FIG. 35.
FIG. 37 is a sectional view of a mine showing friction stabilizers having tabs
deployed in the mine.
FIG. 38 is a bottom plan view of a seventh embodiment of the friction
stabilizer
having an extendable tab.
FIG. 39 is a front elevational view of the of the seventh embodiment of the
friction
stabilizer having the extendable tab.
FIG. 40 is a top plan view of the seventh embodiment of the friction
stabilizer having
the extendable tab.
FIG. 41 is a is a sectional view of the seventh embodiment taken along cut
line cut
line 41-41 as shown in FIG. 40.
FIG. 42 is a sectional view of the seventh embodiment taken along cut-line 42-
42 as
shown in FIG. 38.
FIG. 43 is a sectional view of a mine showing the friction stabilizer having
the
extendable tab.
FIG. 44 shows an enlarged view, partly in section, of FIG. 43.
FIG. 45 is a diagrammatic view of the manufacturing process used for
manufacturing
the friction stabilizer with extendable tabs.
Description
At the outset, it noted that like reference numbers are intended to
identify the same structure, portions, or surfaces consistently throughout the
figures.
It is also noted that when the term "about" is used in connection with
describing a
number that the riumber includes numbers in decimal form that can be rounded
to that
number.
Shown generally in FIGS. 1-6 is the friction stabilizer 20 with tabs 25.
FIG. 4 shows a top plan view of the friction stabilizer with tabs 20. As shown
in
FIGS. 1 and 3, the friction stabilizer with tabs 20 comprises a tubular body
22 having
tabs 25 extending therefrom. The tubular body 22 is elongate and has a first
portion
33 and a second portion 34. The second portion 34 is formed integral joined to
the
first portion 33, and the second portion 34 has a taper 35. The tubular body
22 has an
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impact end 30 and an insertion end 32 that are spaced from one another by the
length,
designated L in FIG. 4, of the tubular body 22. The taper 34 extends from the
insertion end 32 in a direction toward the impact end 30, until it reaches the
first
portion 33. The tubular body 22 may comprise a total length L of about sixty
inches,
about four inches of which comprise the second portion 34 having the taper 35.
The tubular body 22 further comprises an interior surface 24 and an
exterior surface 26, as shown in FIGS. 3 and 5. The interior surface 24
defines a
stabilizer interior 23 internal to the tubular body 22.
As further shown in FIGS. 3 and 5, the tubular body 22 has a first gap
space wall 27 and a second gap space wall 29 which are spaced apart from one
another. The first and second gap space walls 27, 29, respectively, extend
along the
length L of the tubular body 22, from the impact end 30 of the tubular body 22
to the
insertion end 32 of the tubular body 22. The first and second gap space walls,
27, 29,
respectively, define a tube gap space 28 between them, that extends in the
direction of
the of the longitudinal axis, designate X in FIG. 2, of the tubular body 22.
As shown
in FIGS 3 and 5, the tube gap space 28 extends along the length L of the body
22,
from the impact end 30 to the insertion end 32 of the tubular body 22. The
tube gap
space 28 defined between the first and second gap space walls 27, 29 is used
for
allowing tubular body 22 to be compressed radially inward. In a manner to be
described presently, the diameter designated D in FIG. 5, of the tubular body
22
decreases when the tubular body 22 is driven into a drilled bore 50 formed in
a wall
52 or ceiling 54 of a mine 56, as shown in FIG. 37. The drilled bore 50 has a
bore
diameter 51, designated B in FIG. 37, that is less than the diameter D of the
tubular
body 22.
A notch 36 is defined in the taper 35 of the second portion 34 of the
tubular body 22. The notch 36 allows the taper 35 to be formed in the tubular
body
22 at the insertion end 32 thereof when the tubular body 22 is being rolled.
The taper
is used for allowing the insertion end 32 of the tubular body 22 to be
initially fitted
or inserted into the drilled bore 50. After the taper 35 is fitted into the
drilled bore 50,
30 the impact end 30 of the tubular body 22 can be pounded causing the tubular
body 22
to move into the drilled bore 50.
In accordance with the invention, the tubular body 20 comprises tabs
25 that extend from the exterior surface 26 in a direction toward the impact
end 30 of
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the tubular body 20, and away from the insertion end 32 of the tubular body
22. The
tabs 25 work against the removal of the tubular body 22 from a drilled bore 50
in a
mine 56. As a result, the tabs 25 advantageously decrease the likelihood of a
mine 56
cave-in, as will be described presently.
In a preferred embodiment, the tabs 25 are embodied to be rectangular
shaped tabs 40. In particular, there is a first rectangular shaped tab 40a, a
second
rectangular shaped tab 40b, and a third rectangular shaped tab 40c. The first
rectangular shaped tab 40 is positioned closest to the insertion end 32 of the
tubular
body 22, and the third rectangular shaped tab 40c is positioned farthest from
the
insertion end 32 of the tubular body 22, as shown in FIG. 4. The second
rectangular
shaped tab 40b is positioned between the first and second rectangular shaped
tabs 40a,
40c, respectively. The first, second, and third rectangular shaped tabs 40a,
40b, and
40c respectively, are punched out of, laser cut, or otherwise formed in the
tubular
body 22, in ainethod to be described presently.
The first, second, and third rectangular shaped tabs 40a, 40b, and 40c,
respectively, extend outward from the exterior surface 26 of the tubular body
22.
Each rectangular shaped tab 40a, 40b, 40c comprises two parallel tab side
edges 43
and a tab free edge 45 that extends between the tab side edges 43, as shown in
FIG. 7,
which is a top plan view of the flat strip of metal 102 from which the tubular
body 22
is formed. The tab side edges 43 and tab free edges 45 are shown in FIGS. 1,
6, and
7. It is noted that the tabs 40a, 40b, and 40c shown throughout FIGS. 1-6 are
structurally the same.
Each of the rectangular shaped tabs 40a, 40b, and 40c, respectively, is
joined to the tubular body 22 along a bend 44, with the bend being opposite
the tab
free edge 45. The bends 44 are closer to the insertion end 32 of the tubular
body 22
than the tab free edge 45. Each of the rectangular shaped tabs 40a, 40b, and
40c,
respectively, makes an acute angle with the exterior surface 26 of the tubular
body 22,
as shown in FIG. 2. Also, the rectangular shaped tabs 40a, 40b, and 40c,
respectively,
extend in a direction leading away from the insertion end 32 of the tubular
body 22,
and in a direction leading toward the impact end 30 of the tubular body 22, as
shown
in FIG. 2. The rectangular shaped tabs 40a, 40b, and 40c, respectively, are
spaced
apart from one another along the tubular body 22, and are formed in the
tubular body
22 such that they are opposite to the tube gap space 28, as shown in FIG. 6.
It is
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further noted that there are openings 48, as shown in FIG. 2, in the tubular
body 22
under the rectangular shaped tabs 40a, 40b, and 40c, respectively, where they
extend
from the exterior surface 26.
Then, when the tubular body 22 is pounded into a drilled bore 50
insertion end 32 first, the rectangular shaped tabs 40a, 40b, and 40c,
respectively,
bend inward along their bends 44 in a direction toward the openings 48 in the
tubular
body 22. In other words, the rectangular shaped tabs 40a, 40b, and 40c,
respectively,
move back into the tubular body 22 from which they were punched, and thus they
do
not impede the tubular body 22 from being pounded into the drilled bore 50 in
the
wall 52 or ceiling 54 of the mine 56, as shown in FIG. 37. Then, in the event
of a
mine cave-in or wall collapse, the tubular body 22 advantageously remains in
place
and supports the mine wall 52 or ceiling 54, since the rectangular shaped tabs
40a,
40b, and 40c, respectively, resist removal from the drilled bore 50 and dig
into the
surrounding rock. This is due to the fact that the natural spring constant of
the first,
second, and third rectangular shaped tabs 40a, 40b, 40c, respectively, forces
them to
dig into the drilled bore 50.
The three rectangular shaped tabs 40a, 40b, and 40c, respectively, are
spaced along a tubular body 22 about sixty inches long such that the first tab
40a is
about four inches from the insertion end 32 of the tubular body 22, the second
tab 40b
is about fourteen inches from the insertion end 32 of the tubular body 22, and
the third
tab 40c is about twenty-four inches from the insertion end 32 of the tubular
body 22.
The rectangular shaped tabs 40a, 40b, and 40c, respectively, can be sized such
that the
tab side edges 43 are about 0.5 inches long, and the tab free edge 45 is about
1.0 inch.
The rectangular shaped tabs 40a, 40b, and 40c, respectively, advantageously
provide
for a stabilizer 20 that, when installed in a mine, can support greater loads
than
stabilizers having smooth exterior surfaces. Of course, the dimensions may
differ in
other embodiments.
The friction stabilizer 20 further includes a weld ring 31 that in one
embodiment is rectangular shaped, that is, its cross section is rectangular
shaped as
shown in FIGS. 31, 32, and 32a. The rectangular shaped weld ring 31 has a weld
ring
gap space 39 and flat sides 31a. The rectangular shaped weld ring 31 is
positioned
around exterior surface 26 of the tubular body 22 adjacent to the impact end
30
thereof, as shown in FIGS. 1-4. The weld ring gap space 39 is aligned with the
tube
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gap space 28 defined in the tubular body 22. The rectangular shaped weld ring
31 is
welded to the exterior surface 26 of the tubular body 22. The weld 49 that
joins the
tubular body 22 and rectangular shaped weld ring 31 is best shown in FIG. 5.
It is
noted that the weld ring gap space 39 and tube gap space 28 allow for the
tubular
body 22 to be compressed as it is driven into the drilled bore 50 having a
bore
diameter 51 less than the diameter of the tubular body 22. The rectangular
shaped
weld ring 31 is used for supporting a plate 58 in a manner to be described
presently.
In another embodiment, the rectangular shaped weld ring 31 and the tubular
body 22
can be welded together, without the tube gap space 28 and weld ring gap space
39
being aligned.
FIG 5 is a sectional view of the tubular body 22 taken along cut line 5-
5 of FIG. 3, and FIG. 6 is a sectional view of the tubular body 22 taken along
cut line
6-6 of FIG. 3.
It is noted that a circular shaped weld ring 37 having a circular shaped
cross section, as shown in FIGS. 29, 30, and 30a, can be successfully used in
accordance with the present invention. However, the rectangular shaped weld
ring 31
having a rectangular shaped cross section advantageously provides for a higher
quality weld. This is due to the fact that a space 38 can form during the
welding
process under the weld 49 that joins the circular shaped weld ring 37 and the
exterior
surface 26 of the tubular body 22, as shown in FIG. 30a. Additionally, to
successfully
weld the circular shaped weld ring 37 to the tubular body 22, the weld gun
must be
accurately positioned. However, such accurate positioning is oftentimes
difficult to
achieve, because the machinery that does the welding vibrates excessively. As
a
result, the majority of the weld 49 can end up on the circular shaped weld
ring 37 or
on the exterior surface 26 of the tubular body 22. Thus, the weld 49 may end
up
catching only one of the circular shaped weld ring 37 or exterior surface 26
of the
tubular body 22, and/or a space 38 may be formed under the weld 49 as shown in
FIG. 30a.
The rectangular shaped weld ring 31 shown in FIGS. 31, 32, and 32a
advantageously has flat sides 31a. As a result there is no space 38 between
the flat
surfaces 3 la rectangular shaped weld ring 31 and the exterior surface 26 of
the tubular
body 22, since these two surfaces make direct contact with one another leaving
no
room for a space 38 to form under the weld 49. Thus, a high quality weld 49
can be
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made between the flat surfaces 31a of the rectangular shaped weld ring 31 and
exterior surface 26 of the tubular body 22, even in the presence of the
vibrations
generated by the welding machines.
The above-described invention can be variously embodied. FIGS. 8-
12 generally show a second embodiment of the friction stabilizer 20a having
rectangular shaped tabs 40. The tubular body 22a of the second embodiment is
substantially the same as the tubular body 22 of the first embodiment, in that
the
tubular body 22a comprises an exterior surface 26, first and second gap space
walls
27,29, respectively, a tube gap space 28, an impact end 30, an insertion end
32, a
rectangular weld ring 31 having a weld ring gap space 39, a first portion 33,
and a
second portion 34 having a taper 35 having a notch 36. Each rectangular tab 40
of the
second embodiment has parallel tab side edges 43 and a tab free edge 45. The
second
embodiment comprises a row 128 of rectangular shaped tabs 40 that are joined
to the
tubular body 22a at bends 44, and which are spaced from one another at
predetermined spaced intervals, designated I in FIG. 9, along the length L of
the
tubular body 22a. It is noted that the row 128 extends from the side of the
tubular
body 22a opposite the tube gap space 28. As shown in FIGS. 8-10, there are
five
rectangular shaped tabs 40 in the row 128. Of course, in other embodiments,
the row
of tabs 128 may comprise fewer or more than five rectangular shaped tabs 40.
FIG. I 1 is a sectional view of the tubular body of the second
embodiment taken along cut line 11-11 of FIG. 10, and FIG. 12 is a sectional
view of
the tubular body of the second embodiment taken along cut line 12-12 taken of
FIG.
8. The tubular body 22a can be used for supporting the walls 52 and ceiling 54
of a
mine 56 in the same manner as previously described in connection with the
first
embodiment.
FIGS. 13-17 generally show a third embodiment of the friction
stabilizer 20b with tabs. In this embodiment, the tubular body 22b comprises
triangular shaped tabs 41. The tubular body 22b of the third embodiment is
substantially the same as the tubular body 22 of the first embodiment, in that
the
tubular body 22b comprises an exterior surface 26, first and second gap space
walls
27,29, respectively, a tube gap space 28, an impact end 30, insertion end 32,
a
rectangular weld ring 31 having a weld ring gap space 39, a first portion 33,
and a
second portion 34 having a taper 35 having a notch. Each triangular shaped tab
41 of
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the third embodiment has two edges 46 that meet at a point 47, thus forming a
triangle
shape. The triangular shaped tabs 41 are joined to the tubular body 22b at
bends 44,
as shown. There is a row 129 of triangular shaped tabs 41 that extend from the
tubular body 22b at predetermined spaced intervals, designated I in FIG. 13,
along the
length L of the tubular body 22b. It is noted that the row 128 extends from
the side of
the tubular body 22b opposite the tube gap space 28. As shown in FIGS. 13-17,
there
are five triangular shaped tabs 41 in the row 130. In other embodiments, the
row of
triangular shaped tabs 130 may comprise fewer or more than five triangular
shaped
tabs 41.
FIG. 16 is a sectional view taken along cut line 16-16 of FIG. 15, and
FIG. 17 is a sectional view taken along cut line 17-17 of FIG. 13. The tubular
body
22b can be used in the same manner as described above in connection with the
first
embodiment for supporting the walls 52 and ceiling 54 of a mine 56.
FIGS. 18-22 generally show a fourth embodiment of the friction
stabilizer 20c with tabs. In the fourth embodiment, the tubular body 22c
comprises a
plurality of rows 128 of rectangular shaped tabs 40. The rectangular shaped
tabs 40 in
each row 128 are spaced from one another, and the rows 128 are spaced about
ninety
degrees from one another about the exterior surface 26 of the tubular body
22c, as
viewed in sectional figures 21 and 22. The tubular body 22c of the fourth
embodiment is substantially the same as the tubular body 22 of the first
embodiment,
in that the tubular body 22c comprises an exterior surface 26, first and
second gap
space walls 27,29, respectively, a tube gap space 28, an impact end 30,
insertion end
32, a rectangular weld ring 31 having a weld ring gap space 39, a first
portion 33, and
a second portion 34 having a taper 35 having a notch. Each rectangular shaped
tab 40
of the fourth embodiment is joined to the tubular body 22c at a bend 44, and
extends
in a direction toward the weld ring 31. As shown in FIGS. 18-22 there are
three rows
128 of the rectangular shaped tabs 40, with five rectangular shaped tabs 40
per row.
In other embodiments, there can even be more rows 128 of rectangular shaped
tabs 40
provided for on the tubular body 22c, or the number of rectangular shaped tabs
40 in
each row may be increased or decreased.
FIG. 21 is a sectional view taken along cut line 21-21 of FIG. 20, and
FIG. 22 is a sectional view taken along cut line 22-22 of FIG 18. The tubular
body
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CA 02570022 2006-12-05
22c can be used in the same manner as described above in connection with the
first
embodiment for supporting the walls 52 and ceiling 54 of a mine 56.
FIGS. 23-27 generally show a fifth embodiment of the friction
stabilizer 20d. In the fifth embodiment, the tubular body 22d comprises a
plurality of
rows 130 of triangular shaped tabs 41. The tubular body 22d of the fifth
embodiment
is substantially the same as the tubular body 22 of the third embodiment, in
that the
tubular body 22d comprises an exterior surface 26, first and second gap space
walls
27,29, respectively, a tube gap space 28, an impact end 30, insertion end 32,
a
rectangular weld ring 31 having a weld ring gap space 39, a first portion 33,
and a
second portion 34 having a taper 35 having a notch. Each triangular shaped tab
41 of
the fifth embodiment is joined to the tubular body 22d at a bend 44, and
extends away
from the tubular body 22d. The edges 46 of each triangular shaped tab 41 meet
at a
point 47. As shown in FIGS. 23-25 there are three rows 130 of the triangular
shaped
tabs 41, with five tabs 41 per row 130. The rows 130 of triangular shaped tabs
41 are
spaced about ninety degrees from one another about the exterior surface 26 of
the
tubular body 22d, as viewed in FIGS. 26 and 27. In yet other embodiments,
there can
even be more rows 130 of triangular shaped tabs 41 provided for on the tubular
body
22d.
FIG. 26 is a sectional view taken along cut line 26-26 of FIG. 25, and
FIG. 27 is a sectional view taken along cut line 27-27 of FIG. 23. The tubular
bod_v
22d can be used in the same manner as described above in connection with the
first
embodiment for supporting the walls 52 and ceiling 54 of a mine 56.
Shown in FIG. 27A is a sixth embodiment of the friction stabilizer 20e
wherein the tubular body 22e has a plurality of differently shaped tabs 25.
The tabs
25 may be curved shaped tabs, rectangular shaped tabs, triangular shaped tabs,
polygonal shaped tabs, U-shaped tabs, tabs having both curved portions and
linear
portions, semi-circular shaped tabs, hook shaped tabs, parabolic shaped tabs,
combinations of the above, or any other shaped tab that inhibits the
withdrawal of the
friction stabilizer 20e from the drilled bore 50 in the mine 56. The above-
described
tabs 25 may extend in patterns, rows, series, or randomly from the exterior
surface 26
of the friction stabilizer 20e. As shown in FIG. 27A, a plurality of
differently shaped
tabs 25, as described above, extend from the friction stabilizer 20e. In other
embodiments, a single tab 25, for example a rectangular shaped tab 40 or a
triangular
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CA 02570022 2006-12-05
shaped tab 41, may extend from the exterior surface 26 of the friction
stabilizer 20.
The single tab may be any of the above shapes. Thus, the present invention has
significant versatility and may be variously embodied, and all of these
embodiments
are within the scope of the present invention.
In a seventh embodiment shown in FIGS. 38-45, there is a friction
stabilizer 20f having a tubular body 22f. As shown in FIGS. 38-42, the tubular
body
22f is elongate and has a first portion 33 a bent portion 53 and a second
portion 34
with the bent portion 53 joining the first portion 33 and the second portion
34. The
tubular body 22f is preferably formed as one piece. The first portion 33 has
an impact
end 30 and the second portion 34 has an opposed insertion end 32. The first
portion
33 also has a weld ring 31 joined to it with, for example a weld 49, and the
weld ring
31 can have a rectangular or circular cross section. The second portion 34 of
the
tubular body 22f has a taper 35, and the taper 35 extends from the insertion
end 32 in
a direction toward the impact end 30 until it meets with the bent portion 53.
In addition, the tubular body 22f includes an interior surface 24 that is
concave and an opposed exterior surface 26 that is convex, as shown in FIGS.
41 and
42. The interior surface 24 defines a stabilizer interior 23 that is internal
to the
tubular body 22f.
As further shown in FIGS. 38, 41 and 42, the tubular body 22f has a
first gap space wall 27 and a second gap space wall 29 which are spaced apart
from
one another and face one another. As shown in FIG. 39, the first and second
gap
space walls 27, 29, respectively, extend along the length of the tubular body
22f,
designated L in FIG. 39, from the impact end 30 of the tubular body 22f to the
insertion end 32 of the tubular body 22f. A tube gap space 28 extends from the
first
gap space wall 27 to the second gap space wall 29 and the length L of the
tubular
body 22f, from the impact end 30 to the insertion end 32. As shown in FIGS. 40-
43,
the weld ring 31 has a weld ring gap space 39, and the weld ring 31 is welded
to the
first portion 33 with a weld 49, such that the weld ring gap space 39 is
diametrically
opposite the tube gap space 28, as shown in FIG. 41.
In addition, the tubular body 22f is capable of being compressed
radially inward because of the tube gap space 28. In a manner to be described
presently, the diameter of the tubular body 22f designated D in FIG. 39
decreases
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CA 02570022 2006-12-05
when the tubular body 22f is hammered into a drilled bore 50 having a smaller
diameter, designated B in FIG. 43, as will be described in greater detail
presently.
As shown in FIGS. 38, 39 and 42, a notch 36 is defined in the taper 35
of the second portion 34 of the tubular body 22f. The notch 36 extends from
the
insertion end 32 partly into the second portion 34 of the tubular body 22f.
The taper
35 of the second portion 34 increases in the vicinity of the notch 36. Thus,
the tube
gap space 28 decreases in the second portion 34 due to the taper 35, and tube
gap
space 38 decreases an additional amount in the vicinity of the notch 36. This
facilitates introduction of the tubular body 22f into the drilled bore 50. In
addition,
the notch 36 allows the taper 35 to be formed in the tubular body 22f at the
insertion
end 32 thereof when the tubular body 22f is roll formed. After the taper 35 is
fitted
into the drilled bore 50, the impact end 30 of the tubular body 22f can be
hammered
causing the tubular body 22f to move into the drilled bore 50.
The tubular body 22f has a thickness designated TT as shown in FIG.
41 which extends from the exterior surface 24 to the opposed interior surface
26 of
the tubular body 22f.
As shown in FIGS. 38-40 and 42, the tubular body 22f has a single
extendable tab 25b that is joined to the first portion 32 of the tubular body
22f with a
tab joining portion 180. The extendable tab 25b is positioned diametrically
opposite
the tube gap space 28. In addition, and extendable tab 25b is proximal the
bent
portion 37. In particular, the extendable tab 25b is positioned such that
moving from
right to left in FIGS. 38-40, the insertion end 32 is first encountered and
then the
second portion 34 is encountered. Next, the bent portion 53 is encountered,
and then
the first portion 33 is encountered with the tab joining portion 180 and
extendable tab
25b being encountered immediately thereafter. Thus, the extendable tab 25b is
proximal the bent portion 53, but not joined to the bend portion 53. In
addition, the
extendable tab 25b extends in a direction leading away from the insertion end
32 of
the tubular body 22f and in a direction leading towards the impact end 30 of
the
tubular body 22f, as shown in FIGS. 38-40.
As previously mentioned, the tubular body 22f is capable of
compressing radially inward, for example when it is hammered into a drilled
bore 50
having diameter less than that of the tubular body 22f, as will be described
presently.
The tube gap space 28 allows for such inward radial compression of the tubular
body
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CA 02570022 2006-12-05
22f. Thus, the tubular body 22f is capable of moving from a non-compressed
position
190 (as shown in FIGS. 38-42) to a compressed position 192 when hammered into
a
drilled bore.
As shown in FIGS. 38, 40 and 42, the extendable tab 25b has an
interior tab surface 182 and an opposed exterior tab surface 184, and because
the
extendable tab 25b is formed in the tubular body 22f, it also has a thickness
designated TT. The tubular body 22f has an opening 48 in which the extendable
tab
25b is partly positioned. In particular, when the tubular body 22f is in the
non-
compressed position 190 as shown in FIGS. 38- 40 and 42, the extendable tab
25b is
partly positioned in the opening 48, and partly elevated with respect to the
surrounding exterior surface 26 of the tubular body 22f. As shown in FIGS. 39
and
42, the extendable tab 25b extends a minimal amount relative to the
surrounding
exterior surface 26 of the tubular body. Thus, the extendable tab 25b is bent
at the
joining portion 180 such that the extendable tab 25b makes a makes a minimal
angle
with respect to the surrounding exterior surface 26 of the tubular body 22f.
As shown
in FIGS. 39 and 42, when tubular body 22f is in the non-compressed position
190, the
extendable tab 25b is partly in the opening 48 and partly raised or elevated a
minimal
amount relative to the surrounding exterior surface 26 of the first portion
33, as
described above.
When the tubular body 22f is radially compressed and is moved to the
compressed position 192 (for example when hammered into a drilled bore 50 as
will
be described presently and as shown in FIGS. 43 and 44), the extendable tab
25b
bends at the joining portion 180, and the extendable tab 25b moves out of the
opening
48. The extendable tab 25b extends away from the exterior surface 26 the
tubular
body 22f, such that the extendable tab 25b makes an acute angle with the
exterior
surface 26 of the tubular body 22f. Thus, the extendable tab 25b is caused to
move
out of the opening 48 when the tubular body 22f is compressed, and is capable
of
moving from a non-extended position 183, as shown in FIGS. 38-40 and 42, when
the
tubular body 22f is in the non-compressed position 190, to an extended
position 185,
as shown in FIGS. 43 and 44, when the tubular body 22f is in the compressed
position
192.
FIGS 43 and 44 show the friction stabilizer 20f installed in a drilled
bore 50. During installation the insertion end 32 of the tubular body 22f is
introduced
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CA 02570022 2006-12-05
into the drilled bore 50, and the extendable tab 25b is in the above-described
non-
extended position 183. As hammering begins, the tube gap space 28 decreases
and
the tubular body 22f begins to compress radially inward, and the extendable
tab 25b
moves out of the opening 48 and moves to the extended position 185 such that
it
contacts the drilled bore 50. After hammering, the extendable tab 25b engages
the
drilled bore thus increasing the axially holding capacity of the friction
stabilizer 20f.
The extendable tab 25b positioned diametrically opposite the tube gap
space 28 and proximal the bent portion 37, as described above, advantageously
significantly increases the axial load bearing capacity of the tubular body
22f. Two
extendable tabs 25b each positioned diametrically opposite the tube gap space
28 and
each proximal the bent portion 37 as described above also advantageously
significantly increase the holding capacity or axial load bearing capacity of
the
friction stabilizer 20f. The second extendable tab 25b is shown in phantom
lines in
FIG. 40, and as shown, the extendable tabs 25b are proximal to one another . A
third
extendable tab 25b could also be formed in the tubular body 22f is the same
manner
as described above and in line with the other extendable tabs 25b. In other
embodiments there can be more than three extendable tabs 25b each positioned
diametrically opposite the tube gap space 28.
The extendable tab 25f can have any geometry, for example it can be
rectangular shaped as shown in FIG. 38a. It can also be triangle shaped,
curved,
polygonal or virtually any shape that can engage a drilled bore 50.
There are additional advantages associated with the extendable tab
25b. For example, the tubular body 22f is safer to handle in the mine because
the
extendable tab 25b is in the non-extended position 183 prior to introduction
into the
drilled bore 50. Thus, there is a reduced likelihood that mine workers and
factory
works will be injured by the extendable tab 25b. Another advantage is that the
extendable tab 25b does not extend outward from the surrounding exterior
surface 26
of the tubular body 22f until the tubular body 22f has been hammered into the
drilled
bore 50, thus the friction stabilizers 20f can be neatly stacked for shipment.
Another
advantage is the increased axial holding capacity of the friction stabilizer
20f.
To manufacture the friction stabilizer with tabs 20, reference is made
to the schematic shown in FIG. 28. The process or method begins with a coil of
metal, preferably steel or a steel alloy 100. First, a planar or flat strip of
steel 102
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CA 02570022 2006-12-05
pulled from the steel coil, in the direction indicated by the arrows in FIG.
28. The
strip 102 has a width, designated W in FIG. 7, that is about three inches wide
in the
first embodiment. In other embodiments, the width could be more than or less
than
three inches, depending on the particular application or customer requirement.
As the strip of steel 102 is pulled from the coil 100, it moves onto a
conveyor 105. The strip of steel 102 passes through a pressing machine 104
wherein
the tab side edges 43 and tab free edges 45 are pressed into the flat strip of
steel 102.
Pressing machines are well known to those having ordinary skill in the art. It
is to be
understood that the tab side edges 43 and free edges 45 may also be laser cut
or
otherwise formed in the sheet of steel 102 at this point in the manufacturing
process,
by the use of a laser or other device. The shape of the tab 25 is thus formed
in the
sheet of steel 102. It is to be further understood that any desired shape of
the tab 25
could be formed by the pressing machine 104.
The strip 102 is next moved by conveyor 105 through a punching
machine 106 where the notches 36 are punched out of or otherwise formed into
the
flat strip 102. Punching machines 106 are known to those having ordinary skill
in the
art. In another embodiment, the notches 36 could be punched from the strip 102
first,
and then the tabs 40 pressed in the strip 102.
A means for measuring 108 continuously measures the length of the
strip 102 prior to the punching machine 106 so that the notch 36 can be
punched in
the strip 102 at the desired position in the strip 102. The final length of
the friction
stabilizer with tabs 20 is thus determined by the notch 36 location in the
strip 102.
Next, the strip 102 passes from the punching machine 106 and is moved by
conveyor
105 through a cold roll forming mill 110. The cold roll forming mill 110
comprises a
series of stands having top and bottom rolling die 112a, 112b, respectively.
Cold roll
forming mills 110 are known to those having ordinary skill in the art.
As the strip 102 progresses from stand to stand in the cold rolling mill
110 it is formed into a tubular body 22 having the above-described tube gap
space 28.
At the same time, the rectangular shaped tabs 40 begin to move away from the
exterior surface 26 of the continuous tubular body 22z that is being formed in
the cold
rolling mill 110. This is attributed to the fact that the natural spring
constant of the
steel, steel alloy, galvanized steel, or other metal from which the continuous
tubular
body 22z, is made causes the rectangular shaped tabs 40 to extend from the
exterior
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CA 02570022 2006-12-05
surface 26 thereof. It is noted that if the tabs do not extend out, then they
may be
mechanically pushed out of the tubular body 22.
As the continuous tubular body 22z exits the cold roll forming mill
110, the tabs 40 extend from it as previously described and it has notches 36,
but still
has to be cut to the predetermined length. The continuous tubular body 22z is
then
moved by conveyor 105 through a cut-off press 114, where the notch 36 in the
tubular
body 22 signals the cut-off press 114 to cut the tubular body 22 to the
predetermined
length at the notch 36. The length of the tubular body may be about 60 inches
as
shown in FIG. 1 and described in the first embodiment, but in other
embodiments, the
tubular body 22 can be formed to have a length of 18 inches, 24 inches, over
six feet,
or any length required for the particular job, application, or customer order.
The tubular body 22 is then placed on conveyor 105 and transported to
a swaging station 116. At the swaging station 116, the insertion end 32 of the
tubular
body 22, where the notch 36 is located, has pressure applied to it such that
the taper
35 is formed at the insertion end 32. It is noted that the notch 36 provides
the space
for the taper 35 to be formed in the section portion 34 in the swaging station
116.
The tubular body 22 is then moved by a conveyor 105 to a welding
station 118. At the welding station 118 the rectangular shaped weld ring 38 is
fitted
about the impact end 30 of the tubular body 22, such that the weld ring gap
space 39
aligns with the tube gap space 28. In another embodiment the weld ring gap
space 39
and tube gap space 28 are not aligned. While held in this position by the
welding
machine, the tubular body 22 and weld ring 38 are welded together, and thus
joined
by a weld 49. Welding stations 118 are well known to those having ordinary
skill in
that art. After welding, the weld ring 38 is joined with the impact end 30 of
the
tubular body 22. The weld ring gap space 39 may be laser cut or punched out of
the
weld ring 38.
After exiting the welding station 118, the tubular bodies 22 are moved
by conveyor 105 to a packing station 120 having an automatic packaging machine
121. Every other tubular body 22 is then turned end over end and automatically
packaged in bundles 122 of, for example, six tubular bodies 22, by the
automatic
packaging machine 121. Automatic packaging machines 121 are known to those
having ordinary skill in the art. The bundles 122 are transported by conveyor
105 to a
shipping station 124, placed in crates 126, and shipped.
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CA 02570022 2006-12-05
After the friction stabilizer with tabs 20 has been rolled and formed as
described above, the tabs 40 may have sharp tab side edges 43 and tab free
edges 45.
Thus, another step that may be included in the process or method is a grinding
step,
which takes place prior to automatic packing of the tubular bodies 22. During
the
grinding step, any sharp tab side edges 43 and tab free edges 45 are ground
down and
dulled, thus decreasing the likelihood of a worker being cut or injured by the
tabs 40.
The same general method or process is carried out to make the other
embodiments of the friction stabilizer having tabs 20, described above. For
each
embodiment the pressing machine 104 would stamp, punch, or cut edges in the
strip
of steel 102 such that the tab 25 of desired shape may be formed (rectangular
shaped
tabs, triangular shaped tabs, curved shaped tabs, polygonal shaped tabs, U-
shaped
tabs, tabs having both curved portions and linear portions, semi-circular
shaped tabs,
hook shaped tabs, parabolic shaped tabs, combinations of the above, or any
other
shaped tab that inhibits the withdrawal of the friction stabilizer with tabs
20 from the
drilled bore 50 in the mine 56).
To make the friction stabilizer 20f having the tubular body 20f with the
extendable tab 25b, reference is made to the schematic shown in FIG. 45. The
process or method begins with a coil of metal, preferably steel or a steel
alloy 100.
First, a planar or flat strip of steel 102 pulled from the steel coil, in the
direction
indicated by the arrows in FIG. 45. The strip 102 has a width, designated W in
FICi.
7, that is about three inches wide in the first embodiment. In other
embodiments, the
width could be more than or less than three inches, depending on the
particular
application or customer requirement.
As the strip of steel 102 is pulled from the coil 100, it moves onto a
conveyor 105. The strip of steel 102 passes through a pressing machine 104
wherein
the extendable tab 25b is pressed, laser cut or otherwise defined in the flat
strip of
steel 102. Pressing machines are well known to those having ordinary skill in
the art.
The strip 102 is next moved by conveyor 105 through a punching
machine 106 where the notches 36 are punched out of or otherwise formed into
the
flat strip 102. Punching machines 106 are known to those having ordinary skill
in the
art. In another embodiment, the notches 36 could be punched from the strip 102
first,
and then the tabs 40 pressed in the strip 102.
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CA 02570022 2006-12-05
A means for measuring 108 continuously measures the length of the
strip 102 prior to the punching machine 106 so that the notch 36 can be
punched in
the strip 102 at the desired position in the strip 102. The final length of
the friction
stabilizer with tabs 20f is thus determined by the notch 36 location in the
strip 102.
Next, the strip 102 passes from the punching machine 106 and is
moved by conveyor 105 through a cold roll forming mill 111. The cold roll
forming
mill 111 comprises a series of stands having top and bottom extendable tab
rolling die
113a, 113b, respectively. As the strip 102 progresses from stand to stand in
the cold
rolling mill 111 it is formed into a tubular body 22f having the above-
described tube
gap space 28. During cold rolling the extendable tab 25b extends from the
strip 102
only a minimal amount from the exterior surface 26 of the continuous tubular
body
22z that is being formed in the cold rolling mill 111. It is pointed out that
this cold
rolling is different from the above-described cold rolling, in that the
tubular body 22f
is rolled such that the extendable tab 25a does not fully extend outward
during the
cold rolling processes. That is, the cold rolling process is such that it
prevents the full
extension of the extendable tab 25b. Rather, the extendable tab 25b extends
only a
minimal amount from an exterior surface of the continuous tubular body 22z.
The continuous tubular body 22z is then moved by conveyor 105
through a cut-ofTpress 114, where the notch 36 in the tubular body 22 signals
the cut-
off press 114 to cut the tubular body 22f to the predetermined length at the
notch 36.
The length of the tubular body 22f may be about 60 inches as shown in FIG. 1
and
described in the first embodiment, but in other embodiments, the tubular body
22 can
be formed to have a length of 18 inches, 24 inches, over six feet, or any
length
required for the particular job, application, or customer order.
The tubular body 22f is then placed on conveyor 105 and transported
to a swaging and ring station 116. At the swaging and ring station 116, the
insertion
end 32 of the tubular body 22f, where the notch 36 is located, has pressure
applied to
it such that the taper 35 is formed at the insertion end 32, and the weld ring
is
positioned around the continuous tubular body 22z. It is noted that the notch
36
provides the space for the taper 35 to be formed in the section portion 34 in
the
swaging station 116.
The tubular body 22f is then moved by a conveyor 105 to a welding
station 118. At the welding station 118 the weld ring 38 is fitted about the
impact
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CA 02570022 2006-12-05
end 30 of the tubular body 22f, such that the weld ring gap space 39 is
diametrically
opposite the tube gap space 28. While held in this position by the welding
machine,
the tubular body 22 and weld ring 31 are welded together, and thus joined by a
weld
49. After welding, the weld ring 38 is joined with the impact end 30 of the
tubular
body 22.
After exiting the welding station 118, the tubular bodies 22f are moved
by conveyor 105 to a packing station 120 having an automatic packaging machine
121. Every other tubular body 22 is then turned end over end and automatically
packaged in bundles 122 of, for example, six tubular bodies 22f, by the
automatic
packaging machine 121. In addition, because the extendable tab 25b is not
extended,
the bundles can be advantageously readily stacked. Automatic packaging
machines
121 are known to those having ordinary skill in the art. The bundles 122 are
transported by conveyor 105 to a shipping station 124, placed in crates 126,
and
shipped.
To use the friction stabilizer 20 with tabs, a drilled bore 50 is made in a
wall 52 or ceiling 54 of a mine 56 having a floor 55, as shown in FIG. 37. It
is
understood that forming a drilled bore 50 in a mine 56 is known to those
having
ordinary skill in the art. The drilled bores 50 are made in the 52 ceilings
and/or walls
54 of the mine 56. The drilled bore 50 has a diameter, designated B in FIG.
37, which
is less than the diameter of the tubular body 22, designated S and shown in
FIG. 4.
As shown in FIGS. 33 and 34, a plate 58 having a plate opening 60 is
provided. The plate 58 has planar surfaces 59, and is of metal, preferably
steel, steel
alloys, stainless steel, and galvanized steel. The plate opening 60 is sized
such that
the friction stabilizer 22 can be moved through the opening 60. But, the weld
ring 38
is too large to pass through the plate opening 60. The plate 58 is positioned
such that
the opening 60 is brought into alignment with the drilled bore 50 the wall 52
or
ceiling 54, as the case may be, of the mine 56, and held in that position.
Since the
taper 35 at the insertion end 32 of the tubular body 22 has a diameter less
than the
diameter, designated B, of the drilled bore 50, the insertion end 30 of the
tubular body
22 can be readily moved into the drilled bore 50. In particular, the insertion
end 32 is
moved through the opening 60 in the plate 58, such that the taper portion 34
is moved
into the drilled bore 50. However, because the diameter, designated S, of the
tubular
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CA 02570022 2006-12-05
body is greater than the diameter, designated B, of the drilled bore 50, the
first portion
33 of the tubular body 22 must be driven into the drilled bore 50.
To accomplish this, the impact end 30 of the tubular body 22 is driven
by a pneumatic hammer, hydraulic hammer, or other means for hammering or
driving
(not shown) into the drilled bore 50. The tubular body 22 compresses radially
inward
as it is driven into the drilled bore 50, such that the tube gap space 28
decreases.
Additionally, the tabs 40 fold in a direction toward the exterior surface
26 of the tubular body 22, and do not resist insertion of the tubular body 22
into the
drilled bore 50. As a result of tubular body 22 being driven into the lesser
diameter
drilled bore 50, the tubular body 22 compresses radially inward and the tube
gap
space 28 and weld ring gap space 39 both decrease. The tubular body 50 then
exerts
expanding forces against the adjacent surrounding drilled bore wall 51.
Also, in another embodiment shown in FIGS. 35 and 36, the plate
can be a domed-shaped plate 64 having a domed portion 65. The domed portion 65
has an opening 67 for receiving the friction stabilizer 20 there-through.
Contact
surfaces 69 are provided on the domed plate 64 and are used for contacting the
wall
52 or ceiling 54 of the mine 56.
It is noted that as the stabilizer 20 with tabs is driven into the drilled
bore 50, the rectangular shaped tabs 40 move downwardly toward the tubular
body 22
and do not obstruct insertion into the drilled bore 50. However, once driven
into the
drilled bore 50, the tabs 40 force outwardly from the tubular body 22 due to
the
natural spring constant of the steel or other material from which the
stabilizer with
tabs 20 is made. The tabs 40 contact the adjacent surrounding drilled bore
wall 51
and dig into it, resulting in the friction stabilizer with tabs 20 being held
in the drilled
bore 50 by both a friction fit created by the expanding forces generated by
the tubular
body 22, and by the tabs 40 digging into the drilled bore 50.
Then, if force is applied to remove the friction stabilizer with tabs 20,
the tabs 40 immediately dig into the adjacent drilled bore wall 51 and work
against
removal of the stabilizer with tabs 20 from the drilled bore 50. This
significantly
reduces the likelihood that the stabilizer with tabs 20 will work its way out
of the
drilled bore 50 and advantageously significantly increases the amount of
weight or
force the friction stabilizer with tabs 20 can support. Thus the friction
stabilizer with
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CA 02570022 2006-12-05
tabs 20 advantageously decreases the likelihood of a cave-in of walls 52
and/or
ceilings 54 of a mine 56.
In addition, the plate 58, which is trapped between the weld ring 38
and mine wall 52 or ceiling 54 after installation, provides for additional
support of the
surrounding mine walls 52 and ceilings 54, as the case may be. It is noted
that the
plate 58 is supported by the weld ring 38. Thus, if the rock above the plate
58
fractures and weakens, the plate 58 supports the rock, and the plate 58 in
turn is
supported by the friction stabilizer with tabs 20 in the drilled bore 50, and
the tabs 40
advantageously constantly working against removal of the friction stabilizer
with tabs
20 from the drilled bore 51.
The present invention also provided for a mine support system 80. In
particular, the friction stabilizer 20 having tabs can be positioned and
spaced from one
another in drilled bores 50 that are spaced about three feet apart from one
another in
all directions, for example in the walls 52 and ceiling 54 of the mine 56. A
wire mesh
65 is provided. The wire mesh 65 is positioned adjacent to the walls 52 and
ceiling 54
of the mine 56. Then the plates 58 are aligned with the drilled bores 50 in
the manner
described above. Next, the friction stabilizer 20 is driven into the drilled
bore 50 in
the manner previously described. The wire mesh 65 extends between all of the
plates
58 in the mine and is trapped between the plates 58 and the mine wall 52 and
plates
58 and ceiling 54. The wire mesh 65 serves to support any rocks or debris that
break
off of the walls 52 or ceiling 54 of the mine 56. The ability of the wire mesh
65 to
support greater loads is advantageously increased, because the friction
stabilizer
having tabs 40 can support a greater load from the wire mesh 65. Thus, the
stabilizer
with tabs 20 can be used as an, integral part of a mine support system 80 to
prevent
mine 56 cave-ins.
It is noted that the above-described support system 80 can be used in
combination with any of the above-described embodiments of the friction
stabilizer
having tabs 20.
As previously described, in other embodiments the tabs 25 can be any
of a plurality of different shapes (rectangular shaped tabs, triangular shaped
tabs,
curved shaped tabs, polygonal shaped tabs, U-shaped tabs, tabs having both
curved
portions and linear portions, semi-circular shaped tabs, hook shaped tabs,
parabolic
shaped tabs, combinations of the above, or any other shaped tab that inhibits
the
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CA 02570022 2006-12-05
withdrawal of the friction stabilizer with tabs 20 from the drilled bore 50 in
the mine
56).
Additionally, in other embodiments, the rectangular shaped tabs 40 can
be formed such that they extend from the tubular body 22 anywhere from the
exterior
surface 26 of the tubular body 22 including randomly or in patterns. The same
is true
with respect to all of the above-described differently shaped tabs 25, in that
they may
all extend from the tubular body 22 randomly or in patterns. Also, the number
of tabs
25 can be varied regardless of the shape of the tab 25. In addition, the size
of the tab
25 can be varied depending on the requirements of the particular application
in which
the stabilizer 20 will be deployed. In yet other embodiments a single tab 25
having
any of the above described shapes may extend from the tubular body 22. Also,
in
other embodiments the length of the taper 35 of the second portion 34 may be
increased or decreased.
With respect to the seventh embodiment, as shown in FIGS. 43 and 44,
during the hammering process the tubular body 22f compresses radially inward
as it is
hammered into the drilled bore 50, and moves from the non-compressed condition
190 to the compressed condition 192. As this occurs, the extendable tab 25b
moves
out of the opening 48. Stated differently, the extendable tab 25b extends
outward
from the tubular body 22f as the tubular body 22f is hammered deeper into the
drilled
bore 50, and the extendable tab 25b extends into the surrounding drilled bore
50.
When hammering is complete, the extendable tab 25b advantageously extends into
the
drilled bore 50 at a position deep inside the drilled bore 50, advantageously
resulting
in increased axial holding capacity of the friction stabilizer 20f which
prevents mine
collapse.
Also, the diameter of the tubular body 22 of the friction stabilizer with
tabs 20 may be more or less than an inch, but in other embodiments the
diameter of
the stabilizer may be customized to suit particular needs for a particular
application.
The tubular body 22 can comprise various lengths L, for example the sixty inch
length
described above, or a length required for a particular application. For
example, some
mines 56 may require tubular bodies 22 having lengths of twelve, eighteen, or
forty
inches, whereas other mines 56 may require tubular bodies 22 having lengths of
over
two hundred inches. The friction stabilizer having tabs 20 may be used in
these
mining applications. The material from which the stabilizer 20 and weld ring
38 are
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CA 02570022 2006-12-05
made comprises metal, such as steel, steel alloys, galvanized steel, high
strength steel,
metal and metal alloys.
Although a friction stabilizer 20 with tabs has been described, the
present invention could be otherwise embodied without departing from the
principles
thereof, and all such embodiments come with the scope and sprit of the present
invention for a friction stabilizer 20 having tabs.
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