U.S. patent application number 15/395152 was filed with the patent office on 2017-07-06 for overcast system for mine ventilation.
The applicant listed for this patent is FCI Holdings Delaware, Inc.. Invention is credited to Dakota Faulkner, Kevin Jinrong Ma, Lumin Ma, Fred Stafford, John C. Stankus, Richard Wharton.
Application Number | 20170191365 15/395152 |
Document ID | / |
Family ID | 59226166 |
Filed Date | 2017-07-06 |
United States Patent
Application |
20170191365 |
Kind Code |
A1 |
Stankus; John C. ; et
al. |
July 6, 2017 |
Overcast System for Mine Ventilation
Abstract
An overcast system to block an intersection between two or more
mine passageways so as to prevent the mixture of intake air with
return air. The overcast system includes a first sidewall formed of
one or more prefabricated panels, a second sidewall formed of one
or more prefabricated panels, and a top member formed of one or
more prefabricated panels, such that the top side spans the width
between the first sidewall and the second sidewall. A
fire-resistant coating is applied to at least a portion of the
first sidewall, the second sidewall, or the top member to provide
an air-tight, fire-resistant structure. Each of the one or more
prefabricated panels is formed from a composite material having one
or more structural studs embedded at least partially therein.
Inventors: |
Stankus; John C.;
(Canonsburg, PA) ; Wharton; Richard; (Irvona,
PA) ; Stafford; Fred; (New Cumberland, WV) ;
Ma; Lumin; (Pittsburgh, PA) ; Ma; Kevin Jinrong;
(Cheswick, PA) ; Faulkner; Dakota; (New
Kensington, PA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FCI Holdings Delaware, Inc. |
Pittsburgh |
PA |
US |
|
|
Family ID: |
59226166 |
Appl. No.: |
15/395152 |
Filed: |
December 30, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62272748 |
Dec 30, 2015 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21F 1/003 20130101;
E04B 1/948 20130101; E21F 1/14 20130101; E04B 2/60 20130101; E04C
2/205 20130101 |
International
Class: |
E21F 1/14 20060101
E21F001/14; E21F 1/00 20060101 E21F001/00; E04C 2/20 20060101
E04C002/20; E04B 1/94 20060101 E04B001/94; E04B 2/60 20060101
E04B002/60 |
Claims
1. An overcast system comprising: a first sidewall formed of one or
more prefabricated panels; a second sidewall formed of one or more
prefabricated panels; a top member formed of one or more
prefabricated panels, wherein the top member spans the width
between the first sidewall and the second sidewall; and a
fire-resistant coating applied to the first sidewall, the second
sidewall, and the top member; wherein each of the one or more
prefabricated panels is formed of a composite material having one
or more structural studs embedded at least partially therein.
2. The overcast system of claim 1, wherein the composite material
is expanded polystyrene (EPS).
3. The overcast system of claim 1, wherein the one or more
structural studs are S-shaped steel studs.
4. The overcast system of claim 1, wherein each of the one or more
prefabricated panels comprises two structural studs embedded at
least partially therein.
5. The overcast system of claim 1, wherein the fire-resistant
coating is fiber-reinforced composite rock coating.
6. The overcast system of claim 1, further comprising one or more
wing walls attached to the top member.
7. The overcast system of claim 1, further comprising at least one
of a staircase, a ramp, and a ladder.
8. The overcast system of claim 1, wherein each of the one or more
prefabricated panels includes a tongue at one end thereof and
defines a groove at another end thereof for receiving a tongue of
another panel.
9. The overcast system of claim 1, further comprising a wire mesh
applied to at least a portion of a surface of the first sidewall,
the second sidewall, or the top member.
10. The overcast system of claim 1, further comprising a brace
secured to the first sidewall and the top member.
11. The overcast system of claim 1, further comprising a bracket
secured to a sidewall, the bracket being configured for attachment
to a mine floor.
12. A method of forming an overcast system for mine ventilation,
the method comprising: forming a first sidewall using one or more
prefabricated panels; forming a second sidewall using one or more
prefabricated panels, the second sidewall spaced apart from the
first sidewall; forming a top member using one or more
prefabricated panels, the top wall spanning the distance between
the first sidewall and the second sidewall; and applying a
flame-resistant coating to at least a portion of the first
sidewall, the second sidewall, or the top member; wherein each of
the one or more prefabricated panels is formed from a composite
material having one or more structural studs embedded at least
partially therein.
13. The method of claim 11, further comprising securing the first
and the second sidewalls into a bracket attached to a mine floor.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/272,748, filed Dec. 30, 2015, the disclosure of
which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] Field of the Invention
[0003] The present disclosure relates to an overcast system used in
mine ventilation that prevents the mixture of ventilation air at an
intersection of two passageways within a mine. More specifically,
the present disclosure relates to an overcast structure formed of a
plurality of prefabricated panels and coated with spray-on material
to create a substantially air-tight and fire-resistant
structure.
[0004] Description of Related Art
[0005] In underground mining operations, there is a need to provide
a ventilation system such that clean intake air may be introduced
into the mine through a first passageway (or passageways), while
contaminated return air may be removed via a separate, second
passageway (or passageways). As the return air may contain methane,
dust, or other contaminants, it is important that the intersection
between these intake and return air passageways be blocked through
the use of an air-tight partition and/or ducted via an overcast or
undercast structure so as to prevent mixture of the ventilation air
between the two passageways.
[0006] Previously, structures constructed of concrete block or
steel plates were used to define the respective passageways. These
structures were typically sprayed with sealants in an effort to
form an air-tight passageway. However, these structures require
large amounts of material and many hours of labor to construct.
Furthermore, due to the numerous joints between adjacent concrete
blocks and/or steel plates, air leaks were common, leading to both
contamination of the respective passageways and loss of pressure
throughout the ventilation system.
[0007] Efforts have been made to both simplify the installation
process of partition structures and provide for better air sealing
between passageways. For example, U.S. Pat. No. 5,879,231 discloses
an overcast structure formed, in part, from a plurality of
prefabricated panels affixed together. Each panel comprises an
insulated core (e.g., polystyrene) having a plurality of strut
wires passing therethrough, with the strut wires being connected to
respective wire grids on either side of the insulated core. Rebar
is then connected to the wire grids, and a layer of concrete (e.g.,
gunite or shotcrete) is applied over the wire grids and rebar so as
to provide both structural integrity and an air-tight seal to the
overcast.
[0008] While U.S. Pat. No. 5,879,231 may have provided for an
overcast structure having a shortened installation process and
sealing improvements over the previous concrete block and/or steel
plate partitions, the need to provide and assemble the insulated
cores, wire grids, rebar, and concrete coating during installation
still resulted in a complicated and time-consuming process.
Accordingly, an effective overcast system requiring fewer materials
and simplified installation is desired.
SUMMARY OF THE INVENTION
[0009] It is an object of the present disclosure to provide an
overcast system and method that overcomes some or all of the
above-described deficiencies of the prior art.
[0010] One non-limiting embodiment of the disclosure includes an
overcast system having a first sidewall formed of one or more
prefabricated panels, a second sidewall formed of one or more
prefabricated panels, and a top member formed of one or more
prefabricated panels. The top member may span the width between the
first sidewall and the second sidewall. A fire-resistant coating is
applied to at least a portion of the first sidewall, the second
sidewall, or the top member to provide an air-tight, fire-resistant
structure. Additionally, each of the one or more prefabricated
panels is formed from a composite material having one or more
structural studs embedded at least partially therein.
[0011] To facilitate securement of the one or more prefabricated
panels to an adjacent panel, the one or more prefabricated panels
may include a tongue at one end thereof and define a groove at the
other end thereof for receiving a tongue of an adjacent panel. A
brace may be secured to the first sidewall and the top member to
add further structural integrity to the overcast system.
[0012] The composite material may be an expanded polystyrene (EPS).
Each of the one or more prefabricated panels may include two or
more structural studs embedded at least partially therein. The
structural studs may be S-shaped steel studs.
[0013] In one embodiment, a wire mesh is applied to at least a
portion of a surface of the first sidewall, the second sidewall,
and the top member. The fire-resistant coating may be a
fiber-reinforced composite rock coating.
[0014] One or more wing walls may be attached to the top side of
the overcast system, which may include at least one of a staircase,
a ramp, and a ladder for traversing the overcast system.
[0015] Another non-limiting embodiment of the disclosure includes a
method of forming an overcast system for mine ventilation, the
method includes forming a first sidewall using one or more
prefabricated panels, forming a second sidewall using one or more
prefabricated panels, the second sidewall spaced apart from the
first sidewall and forming a top member using one or more
prefabricated panels. The top member spans the distance between the
first sidewall and the second sidewall. The method further includes
applying a flame-resistant coating to at least a portion of the
first sidewall, the second sidewall, and the top member. Each of
the one or more prefabricated panels is formed from a composite
material having one or more structural studs embedded at least
partially therein. The method may additionally include securing the
first and the second sidewalls to a bracket and attaching the
bracket to a mine floor.
[0016] These and other features and characteristics of the present
disclosure, as well as the methods of operation and functions of
the related elements of structures and the combination of parts and
economies of manufacture, will become more apparent upon
consideration of the following description and appended claims with
reference to the accompanying drawings, all of which form a part of
the specification, wherein like reference numerals designate
corresponding parts in various figures. It is to be expressly
understood, however, that the drawings are for the purpose of
illustration and description only and are not intended as a
definition of the limits of the disclosure. As used in the
specification and claims, the singular form of "a," "an," and "the"
include plural referents unless the context clearly dictates
otherwise.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a schematic of a perspective view of an overcast
system installed within an underground mine crosscut;
[0018] FIG. 2 is a perspective view of a prefabricated panel;
[0019] FIG. 3 is a partial top view of the prefabricated panel of
FIG. 2;
[0020] FIG. 4 is a perspective view of an overcast system formed of
prefabricated panels;
[0021] FIG. 5 is a partial cross-sectional view of the overcast
system of FIG. 4 taken along line 5-5 as installed in a mine
entry;
[0022] FIG. 6 is a side view of an overcast system having
connecting cross-bars between prefabricated panels and a wire mesh
thereon;
[0023] FIG. 7 is a partial perspective view of an overcast system
having a ribbed expanded metal form thereon;
[0024] FIG. 8 is a side view of the application of a spray-on
coating on an overcast system; and
[0025] FIG. 9 is a perspective view of the spray-on coating of FIG.
8.
DESCRIPTION OF THE INVENTION
[0026] For purposes of the description hereinafter, the terms
"upper", "lower", "right", "left", "vertical", "horizontal", "top",
"bottom", "lateral", "longitudinal", and derivatives thereof shall
relate to the invention as it is oriented in the drawing figures.
However, it is to be understood that the disclosure may assume
various alternative variations and step sequences, except where
expressly specified to the contrary. It is also to be understood
that the specific devices and processes illustrated in the attached
drawings, and described in the following specification, are simply
exemplary aspects of the disclosure. Hence, specific dimensions and
other physical characteristics related to the aspects disclosed
herein are not to be considered as limiting.
[0027] Referring to FIG. 1, an overcast system 100 in accordance
with an aspect of the present disclosure is shown schematically in
a crosscut of an underground mine. Overcast system 100 comprises a
first sidewall 102, a second sidewall 104, and a top member 106. As
will be set forth in more detail hereinbelow, the first sidewall
102, the second sidewall 104, and the top member 106 may each be
formed of a plurality of interconnectable prefabricated panels. The
first and second sidewall 102, 104 and top member 106 are installed
at an intersection between two passageways (A and B) to define a
first opening 105a and an overpass 105b. Air passing through the
opening 105a along a first path (e.g., directions A in FIG. 1) is
prevented from mixing with air traveling along a second path (e.g.,
directions B in FIG. 1) which includes overpass 105b. The first
sidewall 102 and the second sidewall 104 are formed to be wider
than the entry/opening that they are configured to block. For
example, if the entry/opening width along each passageway is 16
feet, the first sidewall 102 and the second sidewall 104 may be
slightly wider (e.g., 20 to 24 feet) so as to improve the air
sealing qualities of the system 100.
[0028] The top member 106 is constructed to span both the entire
length of the first sidewall 102 and the second sidewall 104 and
the width between respective sidewalls 102, 104, thereby
effectively forming the opening 105a in the first passageway A.
While air moving through the second passageway B is blocked by
sidewalls 102, 104 from mixing with the air moving through the
first passageway A, the air moving through the second passageway B
is allowed to move over the top member 106 via overpass 105b to
continue along the length of the second passageway B. Optional wing
walls 108, 110 may be constructed and attached upon the top member
106 to further direct air through the second passageway B and
minimize air moving through the second passageway B from mixing
with air moving through the first passageway A, and vice versa.
Sidewalls 102, 104, top member 106, and wing walls 108, 110 may be
formed of a plurality of prefabricated panels, as will be discussed
hereinbelow. Furthermore, a pair of staircases 112, 114 may be
installed with system 100 so as to allow personnel to traverse the
overpass 105b of overcast system 100 and move through the second
passageway B. While staircases 112, 114 are shown, it is to be
understood that other features such as ramps, ladders, etc. may be
utilized to enable travel over the overcast system 100. Details of
the components of sidewalls 102, 104 and top member 106 are
described hereafter.
[0029] Referring now to FIG. 2 and FIG. 3, a prefabricated panel
200 in accordance with an aspect of the present disclosure is
shown. As discussed above with respect to FIG. 1, sidewalls 102,
104 and top member 106 may be produced from at least one
prefabricated panel 200, a plurality of which may be interconnected
to form the overcast system 100. Panel 200 includes sidewalls 202
and top side 204 and may be configured for a tongue-and-groove
connection to an adjacent panel (or panels). Specifically, one end
of panel 200 defines a groove 206, while the opposite end of panel
200 includes a tongue 208, thereby enabling construction of a
robust and substantially air-tight connection between adjacent
panels.
[0030] Panel 200 includes a wall 201 that may be formed from a
thermally-efficient material, such as expanded polystyrene (EPS).
Each panel 200 further includes a pair of studs, such as S-shaped
studs 210, 212, which may be formed from steel. Studs 210, 212 may
define openings 213 to accommodate other structural components, as
described below. The openings 213 may be slots, circles, or any
other shape adapted to receive the structural components. An
example of such a prefabricated panel is the ACCEL-E.RTM. Steel
Thermal Efficient Panel from Syntheon, Inc. (Pittsburgh, Pa.). As
shown in FIG. 3, a first portion 214A of each stud 210, 212 is
embedded within the panel 200, while a second portion 214B extends
outside of panel 200 to form a useable stud on one of the sidewalls
202. In this way, S-shaped studs 210, 212 provide strength to the
panel 200 without the need for additional reinforcements, such as
rebar, wire grids, or cement coatings. Furthermore, fasteners are
not needed to affix studs 210, 212 to panel 200, thereby
simplifying the installation process.
[0031] Each stud 210, 212 is for example, spaced two feet apart.
However, it is to be understood that the spacing of studs 210, 212
may be altered as more or fewer studs may be utilized in each panel
200. Furthermore, each panel 200 may come in standard widths (e.g.,
four feet), but may have customizable lengths so as to accommodate
different passageway heights, spans, etc. With such standard
widths, a plurality of prefabricated panels 200 may be condensed
onto a single pallet to be transported through the mine passageways
to the installation site, thereby reducing the time and effort
needed to deliver the materials to be used in construction of an
overcast system.
[0032] Referring to FIG. 4, an overcast system utilizing a
plurality of panels 200 in accordance with an aspect of the present
disclosure is shown. Each panel 200 is configured to be
interconnected to an adjacent panel 200 via at least the
tongue-and-groove connection discussed above with respect to FIG.
2. In FIG. 4, a pair of panels 200 are disposed adjacent one
another so as to form each respective sidewalls 102, 104, while
another pair of panels 200 are disposed adjacent one another and
atop each sidewall 102, 104 so as to form a top member 106 of the
overcast system 100.
[0033] Referring to FIG. 5, an "L" bracket or corner brace 116 may
be fastened between the first sidewall 102 and the top member 106
and between the second sidewall 104 and the top member 106 to
provide further structural reinforcement to the system 100. The
corner brace 116 may be one continuous bracket spanning the length
of the top member 106 or may include a plurality of brackets. The
corner brace 116 may be secured to sidewalls 102, 104 and top
member 106 by one or more self-tapping screws or any other suitable
attachment method commonly known in the art.
[0034] To securely install the overcast system 100, C-shaped
channels 118 are secured to the mine floor by extending one or more
mine bolts 120, through the C-shaped channel 118 and into the mine
floor F, which may be pre-drilled to receive the bolts 120. The
panels 200 are then positioned in the channel 118 such as by
sliding panels 200 into an open end of the C-shaped channel 118 and
engaging the panels 200 thereto, for example, by extending one or
more self tapping screws 215 to the studs 210, 212. The self
tapping screws 215 may vary in length such that the screws 215 are
secured to either the wall 201 or the studs 210, 212, or both the
wall 201 and the studs 210, 212. Securing the panels 200 to the
mine floor F prevents the overcast system 100 from shifting when
pressure in opening 105a increases relative to overpass 105b as may
occur when air flows through first passageway A.
[0035] As shown in FIG. 6, the overcast system 100 may include
reinforcement structures. A pair of panels 200 having respective
walls 201 are shown adjacent one another, with S-shaped studs 210,
212 extending therefrom. To more securely hold the respective
panels together, one or more cross-bar connectors 215 extend
between a stud 212 of one panel and a stud 210 of the adjacent
panel. The cross-bar connectors 215 may have a fixed head and a
terminal nut threaded thereon to engage studs 210, 212. Rotation of
the terminal nut relative to the studs 210, 212 adjusts the
distance between the fixed head and the terminal nut to transition
the cross-bar 215 from an un-tightened position in which the
cross-bar is moveable relative to the studs 210, 212 (FIG. 4 and
FIG. 6) to a tightened position in which the fixed head and the
terminal nut prevent movement of the cross-bar relative to the
shaft to which the cross-bar 215 is attached. This assures that the
panels do not separate, thereby improving the strength and
air-tight qualities of the overcast structure. It is to be
understood that any reasonable means of holding the adjacent panels
together is suitable in accordance with the disclosure.
[0036] In addition, as shown in FIG. 6, panels 200 may be at least
partially covered with wire mesh 220 disposed at or near a surface
of the panels. Unlike prior art panels, the wire mesh 220 is not
meant to provide increased structural integrity to the panels
themselves. Instead, the wire mesh 220 may serve as a structural
support for a fire-resistant spray-on coating to be added after
construction of the overcast structure. The wire mesh 220 may also
act to provide an increased surface area for the spray-on coating
to adhere upon when applied to the overcast structure. By way of a
non-limiting example, the wire mesh 220 may be attached to the
steel studs 210, 212 using, for example, self-drilling screws.
[0037] The wire mesh 220 shown in FIG. 6 is shown as a 1-inch by
1-inch mesh, but it is to be understood that other forms of mesh or
structural support for the spray-on coating may be used in
accordance with various aspects of the disclosure. For example,
referring to FIG. 7, a ribbed metal form 222 such as Stayform.RTM.
available from Alabama Metal Industry Corporation (Birmingham,
Ala.), may be attached to interior surfaces of panels 200 via
suitable fasteners (screws, bolts or the like), not shown. Added
surface members (wire mesh, metal forms, etc.) may be applied to
one or more interior or exterior surfaces of panels 200. Also,
while not shown, a wider mesh, such as a 4-inch by 4-inch mesh, may
be used. Alternatively, no mesh or other structural support may be
used, and the spray-on coating may be applied directly to the
panels 200.
[0038] Referring now to FIG. 8 and FIG. 9, an overcast system 1000
having a spray-on coating is shown. As discussed above, the
spray-on coating is preferably a fire-resistant coating. An example
of a suitable coating is a cementitious, fiber-reinforced composite
rock coating material, such as J-CRETE.RTM. from Jennmar
(Pittsburgh, Pa.). J-CRETE.RTM. is a high-strength (10,000 psi)
Thin Spray-on Liner (TSL) that provides sealing and flame-resistant
qualities to the overcast system 1000. As shown in both FIG. 8 and
FIG. 9, the spray-on coating is applied to at least a portion of
and may be applied to all surfaces of overcast system 1000. Unlike
previous overcast systems utilizing a concrete-based coating, the
spray-on coating of overcast system 1000 does not primarily act as
a structural reinforcement for the system. Rather, the spray-on
coating of overcast system 1000 acts to seal and bond the
prefabricated panels into a single-acting, air-tight,
fire-resistant structure.
[0039] While not shown in FIG. 9, overcast system 1000 may further
comprise a plurality of foam blocks placed between adjacent studs
on the top side of the system prior to application of the spray-on
coating. The foam blocks may be sized to provide an even and level
platform surface on the top side such that after the spray-on
coating is applied and cured, a suitable walking surface is formed
on the top member 106 of the overcast structure 100.
[0040] Although the disclosure has been described in detail for the
purpose of illustration based on what are currently considered to
be the most practical and preferred aspects, it is to be understood
that such detail is solely for that purpose and that the disclosure
is not limited to the disclosed aspects, but, on the contrary, is
intended to cover modifications and equivalent arrangements. For
example, it is to be understood that the present disclosure
contemplates that, to the extent possible, one or more features of
any aspect can be combined with one or more features of any other
aspect.
* * * * *