Non-Contact Boring Using Plasma Torch Exhaust

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Solution Overview

Problem

Existing underground boring technologies face challenges in efficiently removing material without melting rock, especially when dealing with geologies containing high proportions of crystals like SiO2, which require precise control of temperature and pressure to fracture and disintegrate the material effectively.

Innovation Solution

The development of non-contact boring systems that utilize a plasma torch or a cutterhead with a Brayton-cycle turbojet engine to direct high-temperature, high-pressure exhaust gases at the bore face, allowing for precise control of temperature and pressure to fracture and disintegrate rock without melting it, while also using closed-loop controls to maintain optimal boring parameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high temperature and pressure are applied to fracture rock material, then material removal efficiency is improved, but the risk of melting the rock increases

Engineering Contradiction:

Improvematerial removal efficiencyVSAvoidrisk of melting rock

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system dynamically adjusts temperature and pressure parameters of the plasma torch or jet engine exhaust to optimize material removal while preventing melting. The controller modifies operating parameters based on real-time feedback from sensors monitoring the bore face condition, maintaining parameters within a safe operating window that maximizes fracture efficiency without exceeding melting thresholds.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system incorporates sensors that detect the condition of the bore face and provide feedback to the controller. This closed-loop control allows the system to adjust temperature and pressure in real-time, increasing power when material is resistant and reducing it when the rock shows signs of approaching melting, thereby optimizing both productivity and safety.

Inventive Principle:

Principle #23Feedback

2Device complexity

If conventional contact boring methods are used, then equipment simplicity is maintained, but component wear and operational life are reduced

Engineering Contradiction:

Improveequipment simplicityVSAvoidcomponent operating life

Core Design Contradiction:

Device complexityVSDuration of action of stationary object

Solution Approach 1:

The system replaces direct mechanical contact between boring tools and rock with a non-contact thermal and pressure field generated by the plasma torch or jet engine exhaust. This substitution eliminates mechanical wear on cutting components while achieving material removal through thermal fracture and spallation, dramatically extending component operating life despite increased system complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Speed

If material is removed through melting, then boring speed increases, but energy consumption and operational costs increase

Engineering Contradiction:

Improveboring speedVSAvoidenergy consumption

Core Design Contradiction:

SpeedVSUse of energy by moving object

Solution Approach 1:

The system utilizes controlled phase transitions of the rock material through thermal cycling and pressure variations rather than sustained melting. The plasma torch or jet engine exhaust heats the material to fracture temperatures and uses pressure differentials to induce spallation, achieving rapid material removal through phase changes that require less total energy input than complete melting while maintaining high boring speeds.

Inventive Principle:

Principle #36Phase transitions

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

These systems enable efficient removal of material from the bore face through spallation and gasification, minimizing the risk of melting and extending the operating life of components, while reducing energy consumption and operational expenses.

Implementation Method 1

high-temperature, high-pressure exhaust gases at the bore face, allowing for precise control of temperature and pressure to fracture and disintegrate rock without melting it

Methodology Applied

Scientific EffectThermal stress: Thermal Expansion

Implementation Method 2

efficient removal of material from the bore face through spallation and gasification

Methodology Applied

Scientific EffectSpallation: Fracture Mechanics

Implementation Method 3

efficient removal of material from the bore face through spallation and gasification

Methodology Applied

Scientific EffectGasification: Evaporation

Data Source

PatentUS20250067176A1Systems And Methods For Non-Contact Boring

Publication Date: 2025.02.27 PHOENIX BORING INC

AI summary

Disclosed are systems and methods to bore or tunnel through various geologies in an autonomous or substantially autonomous manner including one or more non-contact boring elements that direct energy at the bore face to remove material from the bore face through the fracture, spallation, and removal of the material. Systems can automatically execute methods to control a set of boring parameters that affect the flux of energy directed at the bore face. Systems can further automatically execute the methods to: monitor, direct, maintain, and/or adjust a set of boring controls, including for example a standoff distance between the system and the bore face, a temperature of exhaust gases directed at the bore face, a removal rate of material from the bore face, and/or a thermal or topological characterization of the bore face during boring operations.