U.S. patent application number 13/861054 was filed with the patent office on 2014-10-16 for c-channel panel, overcast, stopping and method.
This patent application is currently assigned to STRATA PRODUCTS WORLDWIDE, LLC. The applicant listed for this patent is Jeremy L. Blackburn, Jeffrey L. Hamrick. Invention is credited to Jeremy L. Blackburn, Jeffrey L. Hamrick.
Application Number | 20140308079 13/861054 |
Document ID | / |
Family ID | 51686906 |
Filed Date | 2014-10-16 |
United States Patent
Application |
20140308079 |
Kind Code |
A1 |
Hamrick; Jeffrey L. ; et
al. |
October 16, 2014 |
C-Channel Panel, Overcast, Stopping and Method
Abstract
A panel includes a core having a top, a bottom, a first side and
a second side. The panel includes a first cap disposed on the top.
The panel includes a second cap disposed on the bottom. The panel
includes a first grid disposed adjacent the first side. The panel
includes a second grid disposed adjacent the second side. The first
cap and the second cap and the first grid and the second grid
defining a frame which envelopes and holds the core without
piercing through the core. A stopping. An overcast. A method for
building a wall.
Inventors: |
Hamrick; Jeffrey L.; (St.
Clairsville, OH) ; Blackburn; Jeremy L.; (Bountiful,
UT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hamrick; Jeffrey L.
Blackburn; Jeremy L. |
St. Clairsville
Bountiful |
OH
UT |
US
US |
|
|
Assignee: |
STRATA PRODUCTS WORLDWIDE,
LLC
|
Family ID: |
51686906 |
Appl. No.: |
13/861054 |
Filed: |
April 11, 2013 |
Current U.S.
Class: |
405/153 ;
405/272; 52/414; 52/741.41 |
Current CPC
Class: |
E04C 2/06 20130101; E04B
2/845 20130101; E21D 11/006 20130101; E21F 1/14 20130101; E02D
29/045 20130101; E21D 11/083 20130101; E04C 2/044 20130101 |
Class at
Publication: |
405/153 ; 52/414;
405/272; 52/741.41 |
International
Class: |
E04C 2/06 20060101
E04C002/06; E04B 2/86 20060101 E04B002/86; E04B 1/16 20060101
E04B001/16; E04B 1/04 20060101 E04B001/04; E02D 29/045 20060101
E02D029/045 |
Claims
1. A panel comprising: a core having a top, a bottom, a first side
and a second side; a first cap disposed on the top; a second cap
disposed on the bottom; a first grid disposed adjacent the first
side; and a second grid disposed adjacent the first side, the first
cap and the second cap and the first grid and the second grid
defining a frame which envelopes and holds the core without
piercing through the core.
2. The panel of claim 1 wherein the first grid is attached to the
first cap and the second cap.
3. The panel of claim 2 wherein the second grid is attached to the
first cap and the second cap.
4. The panel of claim 3 wherein the first cap has a c shaped cross
section defined by a top web and a top first flange and a top
second flange, with the top web disposed on the top of the core,
the top first flange disposed on the first side, and the top second
flange disposed on the second side.
5. The panel of claim 4 wherein the second cap has a c shaped cross
section defined by a bottom web and a bottom first flange and a
bottom second flange, with the bottom web disposed on the top of
the core, the bottom first flange disposed on the first side, and
the bottom second flange disposed on the second side.
6. The panel of claim 5 including mortar or concrete disposed on
the first grid.
7. The panel of claim 6 including a plurality of first bars
disposed adjacent the first side; and a plurality of second bars
disposed adjacent the second side, the first cap and the second cap
and the first grid and the second grid and the first bars and the
second bars defining a frame which envelopes and holds the core
without piercing through the core.
8. The panel of claim 7 wherein the first bars are attached to the
first cap and the second cap.
9. The panel of claim 8 wherein the second bars are attached to the
first cap and the second cap.
10. The panel of claim 9 wherein each first bar is attached to the
top first flange and the bottom first flange.
11. The panel of claim 10 wherein each second bar is attached to
the top second flange and the bottom second flange.
12. An overcast for a miner comprising: sidewalls; decking disposed
on the sidewalls, the decking and sidewalls formed of at least one
panel comprising: a core having a top, a bottom, a first side and a
second side; a first cap disposed on the top; a second cap disposed
on the bottom; a first grid disposed adjacent the first side, the
first cap and the second cap and the first grid and the second grid
defining a frame which envelopes and holds the core without
piercing through the core; and mortar or concrete disposed on the
first grid.
13. A stopping for a tunnel comprising: a plurality of panels, at
least two panels are connected together, at least one panel
comprising: a core having a top, a bottom, a first side and a
second side; a first cap disposed on the top; a second cap disposed
on the bottom; a first grid disposed adjacent the first side, the
first cap and the second cap and the first grid and the second grid
defining a frame which envelopes and holds the core without
piercing through the core; and mortar or concrete disposed on the
first grid.
14. A method for building a wall comprising the steps of: placing a
first panel in a desired position, the first panel comprising a
core having a top, a bottom, a first side and a second side; a
first cap disposed on the top; a second cap disposed on the bottom;
a first grid disposed adjacent the first side; and a second grid
disposed adjacent the first side, the first cap and the second cap
and the first grid and the second grid defining a frame which
envelopes and holds the core without piercing through the core;
placing a second panel adjacent the first panel; connecting the
first panel with the second panel; and applying mortar or concrete
to the first panel and second panel.
Description
FIELD OF THE INVENTION
[0001] The present invention is related to a panel for building
structures that has cement or concrete applied to it. (As used
herein, references to the "present invention" or "invention" relate
to exemplary embodiments and not necessarily to every embodiment
encompassed by the appended claims.) More specifically, the present
invention is related to a panel for building structures that has
cement or mortar or concrete applied to it to build overcasts or
stoppings in a mine, and does not have anything extending through
its core.
BACKGROUND OF THE INVENTION
[0002] This section is intended to introduce the reader to various
aspects of the art that may be related to various aspects of the
present invention. The following discussion is intended to provide
information to facilitate a better understanding of the present
invention. Accordingly, it should be understood that statements in
the following discussion are to be read in this light, and not as
admissions of prior art.
[0003] The construction industry uses prefabricated panels that
serve as a support with the application of cement, such as Gunite
or Shotcrete to form building blocks for walls, floors, ceilings or
roofs, to name but a few of the possible structures. The present
invention is a prefabricated panel that is believed to be better
than existing panels in terms of supporting loads and withstanding
forces that are typically experienced in such structures.
BRIEF SUMMARY OF THE INVENTION
[0004] The present invention pertains to a panel. The panel
comprises a core having a top, a bottom, a first side and a second
side. The panel comprises a first cap disposed on the top. The
panel comprises a second cap disposed on the bottom. The panel
comprises a first grid disposed adjacent the first side. The panel
comprises a second grid disposed adjacent the second side. The
first cap and the second cap and the first grid and the second grid
defining a frame which envelopes and holds the core without
piercing through the core.
[0005] The present invention pertains to an overcast for a mine.
The overcast comprises sidewalls. The overcast comprises decking
disposed on the sidewalls. The decking and sidewalls formed of at
least one panel comprising a core having a top, a bottom, a first
side and a second side. The panel comprises a first cap disposed on
the top. The panel comprises a second cap disposed on the bottom.
The panel comprises a first grid disposed adjacent the first side,
the first cap and the second cap and the first grid and the second
grid defining a frame which envelopes and holds the core without
piercing through the core. The panel comprises mortar or concrete
disposed on the first grid.
[0006] The present invention pertains to a stopping for a tunnel.
The stopping comprises a plurality of panels. At least two of the
panels are connected together. At least one panel comprises a core
having a top, a bottom, a first side and a second side. The one
panel comprises a first cap disposed on the top. The one panel
comprises a second cap disposed on the bottom. The one panel
comprises a first grid disposed adjacent the first side. The first
cap and the second cap and the first grid and the second grid
define a frame which envelopes and holds the core without piercing
through the core. The one panel comprises mortar or concrete
disposed on the first grid.
[0007] The present invention pertains to a method for building a
wall. The method comprises the steps of placing a first panel in a
desired position. The first panel comprises a core having a top, a
bottom, a first side and a second side. The first panel comprises a
first cap disposed on the top. The first panel comprises a second
cap disposed on the bottom. The first panel comprises a first grid
disposed adjacent the first side. The first cap and the second cap
and the first grid and the second grid define a frame which
envelopes and holds the core without piercing through the core.
There is the step of placing a second panel adjacent the first
panel. There is the step of connecting the first panel with the
second panel. There is the step of applying mortar or concrete to
the first panel and second panel.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0008] In the accompanying drawings, the preferred embodiment of
the invention and preferred methods of practicing the invention are
illustrated in which:
[0009] FIG. 1 shows a frame of the panel of the present
invention.
[0010] FIG. 2 shows the panel.
[0011] FIG. 3 shows a portion of the first cap with the first and
second grids and first and second bars.
[0012] FIG. 4 shows a top view of the portion of the first cap.
[0013] FIG. 5 shows a side view of the portion of the first
cap.
[0014] FIG. 6 shows a portion of the first cap.
[0015] FIG. 7 shows a clamp and spacer.
[0016] FIG. 8 shows the clamp and spacer with the clamp unbent.
[0017] FIG. 9 shows a representation of a stopping.
[0018] FIG. 10 shows an exploded view of a representation of an
overcast.
[0019] FIG. 11 is a side view of a representation of an
overcast.
[0020] FIG. 12 is a side view of a representation of an
overcast.
[0021] FIG. 13 is an overhead cutaway view of a representation of a
mine with an overcast and a stopping.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Referring now to the drawings wherein like reference
numerals refer to similar or identical parts throughout the several
views, and more specifically to FIGS. 1 and 2 thereof, there is
shown a panel 10. The panel 10 comprises a core 12 having a top 14,
a bottom 16, a first side 18 and a second side 20. The panel 10
comprises a first cap 22 disposed on the top 14. The panel 10
comprises a second cap 24 disposed on the bottom 16. The panel 10
comprises a first grid 26 disposed adjacent the first side 18. The
panel 10 comprises a second grid 28 disposed adjacent the second
side 20. The first cap 22 and the second cap 24 and the first grid
26 and the second grid 28 define a frame 34 which envelopes and
holds the core 12 without piercing entirely through the core 12.
The one panel 10 comprises mortar or concrete 83 disposed on the
first grid 26.
[0023] The panel 10 may include a plurality of first bars 30, for
example pieces of rebar, disposed adjacent the first side 18. The
panel 10 may include a plurality of second bars 32, for example
pieces of rebar, disposed adjacent the second side 20. The first
cap 22 and the second cap 24 and the first grid 26 and the second
grid 28 and if present, the first bars 30 and the second bars 32,
define a frame 34 which envelopes and holds the core 12 without
piercing through the core 12.
[0024] The first grid 26 may be attached to the first cap 22 and
the second cap 24. The second grid 28 may be attached to the first
cap 22 and the second cap 24. The first bars 30 may be attached to
the first cap 22 and the second cap 24. The second bars 32 may be
attached to the first cap 22 and the second cap 24. The first cap
22 may have c shaped cross section defined by a top web 36 and a
top first flange 38 and a top second flange 40, with the top web 36
disposed on the top 14 of the core 12, as shown in FIGS. 2 and 3.
The top first flange 38 is disposed on the first side 18, and the
top second flange 40 is disposed on the second side 20.
[0025] The second cap 24 may have a c shaped cross section defined
by a bottom web 42 and a bottom first flange 44 and a bottom second
flange 46, with the bottom web 42 disposed on the top 14 of the
core 12. The bottom first flange 44 is disposed on the first side
18, and the bottom second flange 46 is disposed on the second side
20. Each first bar may be attached to the top first flange 38 and
the bottom first flange 44. Each second bar may be attached to the
top second flange 40 and the bottom second flange 46. The panel 10
may include mortar or concrete disposed on the first grid 26 and on
the second grid 28 to a thickness of about 1.5 inches or more.
[0026] The present invention pertains to an overcast 70 for a mine,
as shown in FIGS. 10-13. The overcast 70 comprises sidewalls 71.
The overcast comprises decking 73 disposed on the sidewalls 71. The
decking 73 and sidewalls 71 formed of at least one panel At least
one panel 10 comprises a core 12 having a top 14, a bottom 16, a
first side 18 and a second side 20. The panel 10 comprises a first
cap 22 disposed on the top 14. The panel 10 comprises a second cap
24 disposed on the bottom 16. The panel 10 comprises a first grid
26 disposed adjacent the first side 18. The panel 10 comprises a
second grid 28 disposed adjacent the second side 20. The first cap
22 and the second cap 24 and the first grid 26 and the second grid
28 define a frame 34 which envelopes and holds the core 12 without
piercing entirely through the core 12. The one panel 10 comprises
mortar or concrete 83 disposed on the first grid 26.
[0027] The present invention pertains to a stopping 69 for a
tunnel, as shown in FIG. 9. The stopping 69 comprises a plurality
of panels 10. At least two of the panels 10 are connected together.
At least one panel 10 comprises a core 12 having a top 14, a bottom
16, a first side 18 and a second side 20. The panel 10 comprises a
first cap 22 disposed on the top 14. The panel 10 comprises a
second cap 24 disposed on the bottom 16. The panel 10 comprises a
first grid 26 disposed adjacent the first side 18. The panel 10
comprises a second grid 28 disposed adjacent the second side 20.
The first cap 22 and the second cap 24 and the first grid 26 and
the second grid 28 define a frame 34 which envelopes and holds the
core 12 without piercing entirely through the core 12. The one
panel 10 comprises mortar or concrete 83 disposed on the first grid
26.
[0028] The present invention pertains to a method for building a
wall. The method comprises the steps of placing a first panel 10 in
a desired position. The first panel 10 comprises a core 12 having a
top 14, a bottom 16, a first side 18 and a second side 20. The
panel 10 comprises a first cap 22 disposed on the top 14. The panel
10 comprises a second cap 24 disposed on the bottom 16. The panel
10 comprises a first grid 26 disposed adjacent the first side 18.
The panel 10 comprises a second grid 28 disposed adjacent the
second side 20. The first cap 22 and the second cap 24 and the
first grid 26 and the second grid 28 define a frame 34 which
envelopes and holds the core 12 without piercing entirely through
the core 12. There is the step of placing a second panel adjacent
the first panel 10. There is the step of connecting the first panel
10 with the second panel. There is the step of applying mortar or
concrete to the first panel and second panel.
[0029] In the operation of the invention, the panel 10 is formed by
placing the first cap 22 on the top 14 of the core 12 and the
second cap 24 on the bottom 16 of the core 12. Each cap is 20 feet
long, the web of the cap is 4.75 inches wide, and each flange is 2
inches wide. Each cap is made of 18 gauge steel. The first grid 26
is then placed on the first side 18 of the core 12 by having the
top 14 of the first grid 26 inserted into raised slots 48 on the
top first flange 38 at intervals along its length. Clamps 50 are
then screwed down into the top first flange 38 at intervals along
its length to hold the top 14 of the first grid 26 in place.
Alternatively, the top 14 of the first grid 26 can be welded or
braised or soldered to the top first flange 38 of the first cap 22.
Each grid is formed of welded wire mesh made of 11 gauge steel,
where the mesh is 2 inch by 2 inch. The core 12 is a 2.5 inch or 4
inch thick expanded polystyrene foam as per ASTM C578, incorporated
by reference herein, and which has a flame spread index of 25 or
less. The core 12 made of EPS is an insulation core 12. The length
of the panel 10 is about 20 feet long and 4 feet high.
[0030] The bottom 16 of the first grid 26 is then inserted into
raised slots 48 on the bottom first flange 44 at intervals along
its length. The slots 48 facilitate the proper positioning and
alignment of the grid. Clamps 50 are then screwed down into the
bottom first flange 44 at intervals along its length to hold the
bottom 16 of the first grid 26 in place. Alternatively, the bottom
16 of the first grid 26 can be welded or braised or soldered to the
bottom first flange 44 of the first cap 22. The second grid 28 is
then placed on the second side 20 of the core 12 in the same manner
as the first grid 26 is placed on the first side 18.
[0031] Spacers 52, as shown in FIG. 5, with the clamps 50 are
positioned at intervals on the top first and second flanges and
bottom first and second flanges along their length to maintain a
gap 56 between the grids and the respective surfaces of the core 12
for the cement to properly form on the core 12 and grids, as shown
in FIG. 2. Each clamp 50 has a c portion 54 of metal that defines a
clamp opening 58 through which a grid wire 60 of the top row of
grid wires 60 of the first grid 26 extends, as shown in FIGS. 4 and
5. The c portion 54 is a rectangular strip of metal about 2 inches
long and about 0.5 inches wide and 0.125 inches thick. The c
portion 54 is formed by basically being bent in half. A bottom 16
of the c portion 54 is defined by a first leg 62 and a second leg
64 through which a screw 66 extends to capture the grid wire 60 in
the clamp opening 58 when the screw 66 is tightened down onto the
top first flange 38, as shown in FIGS. 5, 7 and 8. There is a metal
spacer 52, in the form of a block or cylinder that is about 0.5
inches long and about 0.25 inches in diameter disposed between the
clamp 50 and the top first flange 38. The screw 66 extends through
a spacer 52 hole and the first and second legs 62, 64 and the top
first flange 38 to hold the first grid 26 and clamp 50 and spacer
52 in place. The screw 66 is long enough to also penetrate about an
inch into the core 12 when tightened down. This assembly is
repeated at several locations along the top first flange 38, the
top second flange 40, the bottom first flange 44 and the bottom
second flange 46 to secure the first grid 26 at the desired
distance from the first side 18 of the core 12, and the second grid
28 at the desired distance from the second side 20 of the core 12.
The first grid 26 and second grid 28 serve to hold the mortar or
concrete that is placed on the panel 10. Typically, concrete in the
form of Gunite or Shotcrete is sprayed onto each side of the panel
10, as is well-known in the art.
[0032] The top 14 of each piece of rebar on the first side 18 is
welded or braised to or inserted through a flange hole 68 in the
top first flange 38, as shown in FIGS. 1, 2 and 6, and the bottom
16 of each piece of rebar on the first side 18 is also welded or
braised to or inserted through a flange hole 68 in the bottom first
flange 44. Similarly, the top 14 of each piece of rebar on the
second side 20 is welded or braised to or inserted through the top
second flange 40, and the bottom 16 of each piece of rebar on the
second side 20 is welded or braised to or inserted through the
bottom second flange 46. Each piece of rebar is tied or coupled to
the grid at several locations along the piece of rebar's length
with ties 72. The pieces of rebar serve to add structural strength,
rigidity and integrity to the panel 10 so the panel 10 can
withstand the loads typically expected to be placed on it. The
pieces of rebar also serve the dual purpose of being a spacer 52
between the grid and the core 12 to maintain the gap 56 between the
grid and the core 12 for the Gunite to better build up a cement
layer. The rebar has a 3/8 inch diameter and is about 4 feet 1 inch
long. A piece of rebar is typically spaced every three to four feet
along the length of the panel. The rebar is typically used when the
panel is used for decking in an overcast. In a stopping, or side
wall and wing wall of an overcast, when the panel is vertically
oriented relative to the ground, the rebar does not have to be
used.
[0033] The panel 10 may be used for any type of building or
construction applications. Underground, in a tunnel, such as that
found in a mine, the panel 10 can be used for ventilation
structures that include stoppings, overcasts, undercasts and even
seals.
[0034] In the construction of a stopping 69, as shown in FIG. 9,
the site in the mine would first be prepared, as is well-known in
the art. A first panel 10 is placed alongside a seam extending
essentially perpendicular from the seam across the tunnel. Holes
are drilled in the floor alongside the panel 10. Resin capsules are
inserted into the holes and then pieces of rebar are inserted into
the holes which extend from the ground. Each piece of rebar is then
tied to the grid to which it is alongside. In similar fashion, if
the panel 10 placed on the ground does not extend entirely across
the tunnel to the seam on the opposite side, a second panel 100, or
at least a portion of a second panel 100 is placed alongside the
first panel 10 already placed on the ground to extend across the
tunnel between the opposing seams. The first grid 26 on the first
panel 10 and the first grid 26 of the second panel 100 are coupled
together either with ties 72 or couples to link the first panel 10
to the second panel 100. If the width of the tunnel is less than
the length of a single panel 10, then the single panel 10 is cut to
length to essentially extend across the tunnel between the opposing
seams.
[0035] Depending on the height of the tunnel, additional panels may
need to be placed on top of the first panel 10 and the second panel
100, if there is one. In similar fashion, if a third panel 200 is
necessary to close the area of the tunnel above the first panel 10,
the third panel 200 is placed on top of the first panel 10 and the
first grid 26 of the first panel 10 and the first grid 26 of the
third panel 200 are coupled with couplers or ties 72. Similarly, if
a fourth panel 300, or a portion of a fourth panel 300 is needed to
be placed on any second panel 100, then the fourth panel 300 is
coupled in similar manner to the third panel 200 alongside it and
the second panel 100 below it.
[0036] Once the width of the tunnel is essentially closed off, if
it is so desired, holes are drilled into the roof of the tunnel
alongside the front of the third panel 200 and fourth panel 300, if
they are present, or just the first panel 10 if it is the only
panel. Resin capsules can be inserted into the holes and pieces of
rebar then inserted into the holes so they extend from the roof.
The pieces of rebar extending from the roof are then tied or
coupled to the first grid 26 to which they are alongside. In
similar fashion the second side 20 of the stopping 69 formed of the
first panel 10 and any additional panels are connected to rebar
extending from the floor alongside the second side 20, and if
desired from rebar extending from the ceiling. In addition, as
explained in regard to the first side 18, the second grid 28 of
each panel 10 is coupled together. Gunite is then sprayed on each
side of the panels so a layer of at least 1.5 inches, and typically
2 inches, are formed on either side of the panels that make up the
stopping 69. The Gunite is also applied along the edges of the
panels alongside the seams so any openings or aps between the sides
of the panels or panel, are closed off and create a seal,
preventing any airflow past the stopping. The application of Gunite
is well-known in the art.
[0037] In a similar manner an overcast 70, or undercast can be
formed in an intersection of tunnels, for instance in a mine. See
FIGS. 10-13. The sidewalls 71 are formed in the same way as
described above for the stopping 69. The decking 73 of the overcast
70 is formed by placing panels flat alongside each other
horizontally across the width of the tunnel with their sides
disposed on top of the sidewalls 71 and supported by the sidewalls
71. The panels alongside each other form the decking 73 are tied or
coupled together through their respective grids, first grid to
first grid and second grid to second grid.
[0038] If one or more wing walls 75 are needed to close off air
flow around the side walls 71, the wing walls 75 are built the same
way as the walls for stopping, with the wing wall 75 built high
enough to reach the seam. Pieces of rebar may be inserted into
holes drilled into the seam with resin capsules to hold the rebar.
The wing wall 75 can be tied to the rebar pieces. The sidewalls 71
and decking 73 and any wing walls 75 and gaps between them and the
seams are sprayed with Gunite to a thickness of at least 1.5 inches
and preferably 2 inches, to form an air tight seal and solid
support structure that can withstand loads and forces of at least
15 psi.
[0039] Although the invention has been described in detail in the
foregoing embodiments for the purpose of illustration, it is to be
understood that such detail is solely for that purpose and that
variations can be made therein by those skilled in the art without
departing from the spirit and scope of the invention except as it
may be described by the following claims.
* * * * *