HDPE Rib Support Device for Underground Mining Spalling Prevention
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Solution Overview
Problem
Existing rib support systems in underground mining and tunneling face challenges with corrosion susceptibility, sharp edges, and increased failure rates due to increased pressure at deeper depths, leading to spalling and potential roof collapse, which poses safety risks and longevity issues.
Innovation Solution
A rib support system utilizing high-density polyethylene (HDPE) materials for the support device, featuring a longitudinal strap with slots and a cross-sectional angle of curvature, combined with fasteners, providing corrosion resistance, superior strength, and safety without sharp edges, along with a manufacturing method involving molding and inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal rib support structures are used, then structural strength is improved, but corrosion susceptibility increases
Solution Approach 1:
The patent employs a composite support structure consisting of a steel cable or rod encased in a protective covering or sheath. The steel core provides the necessary tensile strength to support the rib, while the outer covering protects against corrosion from moisture and chemical exposure in the mining environment. This composite approach combines the advantages of metal strength with corrosion resistance.
2Strength
If metal rib support structures are used, then structural strength is improved, but spark generation increases
Solution Approach 1:
The steel cable or rod is enclosed in a non-metallic protective covering that prevents direct contact between the metal and the rock rib. This isolation eliminates the spark-generating contact that occurs when metal supports rub against or impact the rib, while the steel core continues to provide the necessary structural strength.
3Reliability
If concrete structures are used for rib support, then corrosion resistance is improved, but weight increases
Solution Approach 1:
The patent uses a flexible or semi-flexible protective covering or sheath that encases the steel cable or rod. This thin-walled covering provides corrosion protection similar to concrete but with significantly reduced weight. The covering can be made from materials such as plastic, rubber, or other polymer-based substances that offer environmental protection while maintaining flexibility and low weight.
4Stress or pressure
If rib support systems are designed for deeper strata, then pressure resistance is improved, but failure rate increases
Solution Approach 1:
The composite structure of a steel core within a protective covering creates a more reliable support system for deep strata. The steel cable or rod is specifically selected with high tensile strength properties to withstand the increased pressures and stresses encountered at greater depths, while the protective covering ensures the metal remains free from corrosion that would compromise its strength over time, thereby reducing failure rates.
Data Source
AI summary
A rib support system, a rib support device, a rib support method, a method for manufacturing a rib support device, and a computer readable medium are provided as described herein. The rib support device is configured to support a mine or tunnel rib (or wall) or roof to prevent spalling, and to provide safety and long term protection of tunnel (or open) areas. The rib support device may be made from a high density polyethylene (HDPE) material, or the like, that is resistant to corrosion, has superior overall performance and strength, has few (or no) sharp edges, is light weight, and is easy to handle.