Rock Bolt Device with Replaceable Head

Abstract

A rock bolt device with replaceable head is provided comprised of an enhanced rock bolt assembly for ground support in mining and tunneling, designed to address bolt head damage, mesh displacement, and repair complexities while ensuring continuous structural stability and safety. The assembly comprises a threaded bolt shaft, a bolt head, a face plate, a wire mesh, and a flange that secures the plate and mesh. The face plate distributes load evenly across the rock surface, stabilizing loose rock, while the mesh, positioned behind the plate, remains tensioned and securely clamped, preventing sagging or dislodgement even in case of bolt head failure. The flange, serving as a secondary anchoring point, incorporates a calibrated weak point designed to fail cleanly upon impact, enabling bolt head detachment without damaging the bolt shaft or plate. The bolt head can be replaced by re-engaging fasteners, simplifying repairs and reducing costs.

Claims

1. A rock bolt device with replaceable head comprising: a bolt comprised of a bolt shaft and a bolt head; a face plate; and a flange positioned between the bolt head and the face plate, wherein the bolt head is configured to detach at a weak point on the flange upon impact to enable the bolt head to detach without damaging the bolt shaft or the face plate.

2. The rock bolt device with replaceable head of claim 1, wherein the face plate is flat.

3. The rock bolt device with replaceable head of claim 1, wherein the bolt head is attached to the flange.

4. The rock bolt device with replaceable head of claim 1, wherein the flange is comprised of a corrosion-resistant coating.

5. A rock bolt device with replaceable head comprising: a bolt comprised of a bolt shaft and a bolt head; a wire mesh; a face plate; and a flange positioned between the bolt head and the face plate, wherein the bolt head is configured to detach at a weak point on the flange upon impact to enable the bolt head to detach without damaging the bolt shaft or the face plate.

6. The rock bolt device with replaceable head of claim 5, wherein the wire mesh is comprised of an interwoven steel wire.

7. The rock bolt device with replaceable head of claim 5, wherein the wire mesh is comprised of a reinforced composite grid.

8. The rock bolt device with replaceable head of claim 5, wherein the wire mesh is positioned behind the face plate.

9. The rock bolt device with replaceable head of claim 5, wherein a perimeter of the wire mesh is comprised of a reinforced binding.

10. The rock bolt device with replaceable head of claim 5, wherein the flange is comprised of a first fastener.

11. The rock bolt device with replaceable head of claim 10, wherein the bolt head is comprised of a second fastener.

12. The rock bolt device with replaceable head of claim 11, wherein the first fastener and the second fastener are comprised of a pair of reciprocating fasteners.

13. The rock bolt device with replaceable head of claim 12, wherein the first fastener and the second fastener are comprised of a notch and a groove.

14. The rock bolt device with replaceable head of claim 5, wherein the wire mesh is comprised of an anti-corrosion coating.

15. The rock bolt device with replaceable head of claim 14, wherein the anti-corrosion coating is comprised of a zinc or an epoxy.

16. The rock bolt device with replaceable head of claim 5, wherein the face plate is flat.

17. The rock bolt device with replaceable head of claim 5, wherein the flange and the bolt head form an angle between 1 and 179 degrees relative to the bolt shaft.

18. A method of using a rock bolt device with replaceable head, the method comprising the following steps: providing a rock bolt device with replaceable head comprised of a bolt, a bolt shaft, a bolt head, a face plate, a wire mesh, and a flange; placing the wire mesh over a rock surface; inserting the bolt shaft into a pre-drilled hole in the rock surface to anchor the bolt securely in place over the wire mesh; applying torque to the bolt head to secure the face plate and the wire mesh against the rock surface; detaching the bolt head and the flange as a single unit from the bolt shaft when the bolt head becomes damaged or shears off; and re-attaching a replacement bolt head assembly to the flange to restore the functionality of the rock bolt device.

19. The method of using a rock bolt device with replaceable head of claim 18, wherein the replacement bolt head assembly is re-attached to the flange without removing the bolt shaft from the rock surface.

20. The method of using a rock bolt device with replaceable head of claim 18, wherein the replacement bolt head assembly is identical in structure to the original bolt head.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The description refers to provided drawings in which similar reference characters refer to similar parts throughout the different views, and in which:

[0017] FIG. 1 illustrates a perspective view of one potential embodiment of a rock bolt device with replaceable head of the present invention in accordance with the disclosed architecture;

[0018] FIG. 2 illustrates a perspective view of one potential embodiment of a rock bolt device with replaceable head of the present invention while secured into a rock surface with the wire mesh covering the rock surface in accordance with the disclosed architecture; and

[0019] FIG. 3 illustrates a flowchart of a method of using one potential embodiment of a rock bolt device with replaceable head of the present invention in accordance with the disclosed architecture.

DETAILED DESCRIPTION

[0020] The innovation is now described with reference to the drawings, wherein like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding thereof. It may be evident, however, that the innovation can be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form to facilitate a description thereof. Various embodiments are discussed hereinafter. It should be noted that the figures are described only to facilitate the description of the embodiments. They are not intended as an exhaustive description of the invention and do not limit the scope of the invention. Additionally, an illustrated embodiment need not have all the aspects or advantages shown. Thus, in other embodiments, any of the features described herein from different embodiments may be combined.

[0021] As noted above, there exists a long-felt need in the art for a rock bolt device with replaceable head that maintains the stability of the face plate and wire mesh even if the bolt head is removed due to impact. There also exists a long-felt need in the art for a rock bolt device with replaceable head that allows for the quick replacement of a damaged bolt head without requiring the removal of the entire assembly. Moreover, there exists a long-felt need in the art for a rock bolt device with replaceable head that withstands harsh underground conditions and minimizes maintenance requirements while ensuring continuous ground support.

[0022] The present invention, in one exemplary embodiment, is comprised of a rock bolt device with replaceable head. The invention relates to an improved rock bolt design for ground support systems in mining and tunneling, addressing challenges such as bolt head damage, mesh dislodgement, and repair complexity while enhancing stability, safety, and maintenance efficiency.

[0023] The device includes a rock bolt assembly comprising a bolt shaft, bolt head, face plate, wire mesh, and a flange. The bolt shaft, formed as a threaded rod, acts as the primary anchoring element when inserted into pre-drilled holes in the rock surface. The bolt head, positioned at the exposed end, enables torque application and secures the face plate and mesh. The face plate distributes the load evenly across the rock surface, stabilizing loose rock and holding the mesh securely. Positioned behind the face plate, the wire mesh remains tensioned and conforms to uneven surfaces, with reinforced edges to prevent fraying and withstand dynamic loads.

[0024] The flange, located between the bolt head and shaft, serves as a secondary anchoring point for the face plate and mesh. The connection between the flange and bolt shaft incorporates a calibrated weak point that allows clean detachment of the bolt head upon impact, preventing damage to the remaining assembly. Reciprocating fasteners, such as notches or grooves, facilitate reattachment of a replacement bolt head without removing the entire assembly.

[0025] The device components are constructed from durable, corrosion-resistant materials, including heat-treated steel for the bolt shaft and reinforced steel alloy with protective coatings for the flange. The wire mesh may also be treated with anti-corrosion coatings to withstand harsh underground environments.

[0026] The invention offers several advantages over conventional systems, such as maintaining ground support even if the bolt head fails, preventing mesh dislodgement, and reducing repair costs through its modular design. The simplified replacement process for damaged bolt heads minimizes downtime and material waste, improving safety by maintaining consistent support and preventing debris-related hazards.

[0027] The method of use involves placing the wire mesh over the rock surface, anchoring the bolt shaft into a pre-drilled hole, and applying torque to secure the assembly. If the bolt head is damaged, the weakened connection allows for its clean removal and replacement, restoring functionality without disassembling the entire system.

[0028] The rock bolt device with replaceable head is particularly beneficial due to its support flange, which keeps the face plate and mesh secure even if the bolt head detaches. The calibrated weak point in the bolt assembly enables efficient replacement of the bolt head, avoiding damage to other components. The modular design significantly reduces repair costs and operational downtime, addressing the limitations of existing rock bolts in the field.

[0029] Referring initially to the drawings, FIG. 1 illustrates a perspective view of one potential embodiment of a rock bolt device 100 with replaceable head of the present invention in accordance with the disclosed architecture. The present invention relates to an improved design for rock bolts used in ground support systems, particularly in mining and tunneling applications. The invention further incorporates specific features aimed at addressing common issues such as bolt head damage, mesh dislodgement, and maintenance complexity. The invention further ensures continuous stability, safety, and ease of repair while minimizing operational disruptions.

[0030] The device 100 is comprised of a rock bolt assembly comprising a bolt 101 having a bolt shaft 102, a bolt head 104 (of any type/style), a face plate 106, and a wire mesh 108. The bolt shaft 102 is comprised of a threaded rod that is inserted into pre-drilled holes in a rock surface during use to serve as a primary anchoring element. The bolt head 104, located at the exposed end of the bolt shaft 102, is used to apply torque during installation and to secure the face plate 106 and wire mesh 108. As noted, in mining environments, the bolt head 104 often protrudes from the rock surface, making it prone to damage from passing vehicles. Such damage can render the entire rock bolt ineffective, requiring replacement or repair.

[0031] The face plate 106 is a flat metal element placed between the rock surface and the bolt head 104, wherein the face plate 106 is comprised of an opening 107 that allows the shaft 102 to pass through. The face plate 106 distributes the load applied by the bolt 101 evenly across the rock surface, stabilizing loose rock and holding the wire mesh 108 securely in place, as seen in FIG. 2. The wire mesh 108, which may be comprised of interwoven steel wires or a reinforced composite grid, is positioned behind the face plate 106. In this configuration, the mesh 108 is clamped securely between the face plate 106 and rock surface. This arrangement ensures that the mesh 108 remains tensioned and pressed uniformly against the rock surface, even in the event of bolt head 104 failure. The mesh 108 preferably has a fine-to-medium weave to contain various sizes of debris while maintaining flexibility to conform to uneven rock surfaces. The perimeter edges of the mesh 108 may feature reinforced bindings 109 to prevent fraying and to withstand dynamic load conditions. Together with the bolt 101 and plate 106, the wire mesh 108 forms a comprehensive support structure for securing rock surfaces, providing effective stabilization of both small and large fragments of rock.

[0032] The device 100 is also comprised of a flange 110 positioned between the face plate 106 and the bolt head 104. This fixed flange 110 serves as a secondary anchoring point for the plate 106, ensuring that these components remain in position even if the bolt head 104 is damaged or sheared off. By positioning the mesh 108 behind the face plate 106, the device 100 provides an additional layer of security by preventing the mesh 108 from slipping out of place, even during sudden impacts or structural shifts. The flange 110 and bolt head 104 may form an angle between 0 and 180 degrees relative to the vertical or horizontal axis of the shaft 102.

[0033] The interface between the flange 110 and the bolt shaft 102 is engineered as a calibrated weak point when the flange 110 is fixed to the bolt head 104. The flange 110 and bolt head 104 may be comprised of a pair of reciprocating fasteners 120, 122 (as seen in FIG. 2) such as, but not limited to, a notch or a groove. This weak point is designed to fail cleanly under impact, allowing the bolt head 104 to detach from the flange 110 without causing damage to the shaft 102 or the plate 106. This feature simplifies repair processes and prevents collateral damage to the rest of the assembly, as bolt head 104 can simply be re-attached to the flange 110 using the fasteners 120, 122. In one embodiment, the flange 110 is fixedly attached to the bolt head 104, wherein the flange 110 then attaches to the shaft 102 in the same manner that the flange 110 would attach to the bolt head 104 as described immediately above. In one embodiment, the flange 110 is fixedly attached to the shaft 102 and the bolt head 104 removably attaches to the flange 110.

[0034] The materials used in the construction of the device 100 are selected for durability and resistance to harsh underground conditions. The flange 110 is constructed from a reinforced steel alloy with a corrosion-resistant coating 112, such as zinc or epoxy, to prevent degradation. The bolt shaft 102 is fabricated from high-tensile steel that is heat-treated to withstand heavy loads. The wire mesh 108 may be treated with anti-corrosion coatings 111, such as galvanized zinc or epoxy, to prevent rust and degradation from prolonged exposure to moisture and harsh conditions.

[0035] As a result, the device 100 offers several advantages over conventional rock bolts. The integration of the flange 110 ensures that the face plate 106 and mesh 108 remain functional even if the bolt head 104 is compromised, providing continuous ground support. The invention also prevents the mesh 108 from sagging or becoming dislodged, which is critical for safety in active mining and tunneling environments. The modular design of the device 100 reduces repair costs, as only the damaged bolt head 104 needs to be replaced, significantly lowering material and labor expenses. Furthermore, by maintaining mesh tension and preventing dislodgement, the invention improves overall safety and minimizes the risk of injury caused by loose rock fragments.

[0036] The present invention is also comprised of a method of using 200 the device 100, as seen in FIG. 3. First, a device 100 is provided comprising a bolt 101, a bolt shaft 102, a bolt head 104, a face plate 106, a wire mesh 108, and a flange 110 [Step 202]. Then the fire mesh 108 is placed over a rock surface [Step 204]. Next, the bolt shaft 102 is inserted into a pre-drilled hole in a rock surface to anchor the device 100 securely in place over the mesh 108 [Step 206]. Torque is then applied to the bolt head 104 to tighten the assembly, securing the face plate 106 and the wire mesh 108 against the rock surface [Step 208]. If the bolt head 104 becomes damaged or shears off, the weakened interface between the flange 110 and the bolt shaft 102 allows for a clean detachment of the bolt head 104 and flange 110 as a single unit. Once the damaged bolt head 104 is removed, a replacement bolt head 104 assembly can be re-attached to the flange 110 by engaging the fasteners 120, 122, which may include notches, grooves, or threaded connectors [Step 210]. This replacement process restores the functionality of the device 100 without requiring the removal of the entire bolt assembly, significantly reducing repair time and material waste.

[0037] Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not structure or function. As used herein rock bolt device with replaceable head and device are interchangeable and refer to the rock bolt device with replaceable head 100 of the present invention.

[0038] Notwithstanding the foregoing, the rock bolt device with replaceable head 100 of the present invention and its various components can be of any suitable size and configuration as is known in the art without affecting the overall concept of the invention, provided that they accomplish the above-stated objectives. One of ordinary skill in the art will appreciate that the size, configuration, and material of the rock bolt device with replaceable head 100 as shown in the FIGS. are for illustrative purposes only, and that many other sizes and shapes of the rock bolt device with replaceable head 100 are well within the scope of the present disclosure. Although the dimensions of the rock bolt device with replaceable head 100 are important design parameters for user convenience, the rock bolt device with replaceable head 100 may be of any size, shape, and/or configuration that ensures optimal performance during use and/or that suits the user's needs and/or preferences.

[0039] Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present invention. While the embodiments described above refer to particular features, the scope of this invention also includes embodiments having different combinations of features and embodiments that do not include all the described features. Accordingly, the scope of the present invention is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof.

[0040] What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art may recognize that many further combinations and permutations of the claimed subject matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term includes is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term comprising as comprising is interpreted when employed as a transitional word in a claim.