Torque Nut Injection-Molded Breakaway Insert Mine Roof Support
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Solution Overview
Problem
Conventional torque nuts used in mine roof support require degreasing and the use of release agents, which complicates their manufacturing and storage, and involves a time-consuming curing process.
Innovation Solution
A torque nut with an injection-molded breakaway insert that eliminates the need for degreasing and release agents, featuring a method where the insert is molded into the nut body with internal threads, allowing for easy release and reduced friction, enabling faster production and use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin plug is used in the nut to fracture the capsule and mix resin and catalyst, then the anchor can be secured in the bore hole, but the nut requires degreasing and release agents which complicates manufacturing and storage
Solution Approach 1:
The patent extracts the resin plug from the nut body, replacing it with a breakaway insert made of a different material (such as plastic or polymer). This insert is injection-molded directly into the nut, eliminating the need for degreasing and release agents while maintaining the function of fracturing the capsule and mixing resin and catalyst.
Solution Approach 2:
The patent changes the material parameter of the insert from cured resin to a thermoplastic or polymer material that can be injection-molded. This parameter change allows the insert to be securely attached to the nut body without requiring degreasing or release agents, simplifying the manufacturing process while maintaining reliable performance.
2Reliability
If a resin plug is used in the nut, then the capsule can be fractured and resin mixed, but time-consuming curing process is required before storage
Solution Approach 1:
The patent removes the cured resin plug from the nut body and replaces it with a breakaway insert made of thermoplastic or polymer material. This insert can be injection-molded directly into the nut without requiring a curing process, eliminating the time delay before storage while maintaining the functionality of fracturing the capsule and mixing resin and catalyst.
Solution Approach 2:
The patent changes the material state from cured thermoset resin to thermoplastic or polymer material that can be processed by injection molding. This parameter change eliminates the curing time requirement, allowing immediate storage and use of the nuts without waiting for the resin to cure.
3Strength
If degreasing and release agents are used to secure the plug in the nut, then the plug bonds to the inner surface, but the process becomes more complex and storage requirements increase
Solution Approach 1:
The patent extracts the degreasing and release agent steps from the manufacturing process by using a breakaway insert made of thermoplastic or polymer material that can be injection-molded directly into the nut. The insert is secured through the injection molding process itself, eliminating the need for degreasing and release agents while maintaining secure attachment.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (degreasing and release agents) with a mechanical bonding mechanism (injection molding). The thermoplastic or polymer insert is mechanically secured to the nut body through the injection molding process, eliminating the need for chemical treatments while maintaining strong attachment.
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
The solution simplifies the manufacturing process, reduces storage time, and ensures consistent performance by eliminating the need for degreasing and release agents, while allowing for efficient securing of anchors in mine roofs and other structures.
Implementation Method 1
an injection-molded breakaway insert is in the passageway, with periphery of the insert engaging apexes of selected ones of the internal threads
Data Source
AI summary
A nut having an injection-molded insert or delay stopper is threaded onto an end of an anchor. A capsule containing a resin component and a catalyst component and the other end of the anchor are positioned in a bore hole in a mine roof, mine wall, side of a hill, concrete wall, or concrete floor. The threaded end of the nut contacts the insert and rotation of the nut rotates the anchor, breaking the capsule and mixing the components. After the components set, increased torque is applied to fracture the insert and move the nut up the threaded end of the shaft against roof stabilizing components on the shaft.