C-Channel Panel, Overcast, Stopping and Method

Abstract

A panel includes a core having a top, a bottom, a first side and a second side. The panel includes a first cap disposed on the top. The panel includes a second cap disposed on the bottom. The panel includes a first grid disposed adjacent the first side. The panel includes a second grid disposed adjacent the second side. The first cap and the second cap and the first grid and the second grid defining a frame which envelopes and holds the core without piercing through the core. A stopping. An overcast. A method for building a wall.

Description

FIELD OF THE INVENTION

The present invention is related to a panel for building structures that has cement or concrete applied to it. (As used herein, references to the “present invention” or “invention” relate to exemplary embodiments and not necessarily to every embodiment encompassed by the appended claims.) More specifically, the present invention is related to a panel for building structures that has cement or mortar or concrete applied to it to build overcasts or stoppings in a mine, and does not have anything extending through its core.

BACKGROUND OF THE INVENTION

This section is intended to introduce the reader to various aspects of the art that may be related to various aspects of the present invention. The following discussion is intended to provide information to facilitate a better understanding of the present invention. Accordingly, it should be understood that statements in the following discussion are to be read in this light, and not as admissions of prior art.

The construction industry uses prefabricated panels that serve as a support with the application of cement, such as Gunite or Shotcrete to form building blocks for walls, floors, ceilings or roofs, to name but a few of the possible structures. The present invention is a prefabricated panel that is believed to be better than existing panels in terms of supporting loads and withstanding forces that are typically experienced in such structures.

BRIEF SUMMARY OF THE INVENTION

The present invention pertains to a panel. The panel comprises a core having a top, a bottom, a first side and a second side. The panel comprises a first cap disposed on the top. The panel comprises a second cap disposed on the bottom. The panel comprises a first grid disposed adjacent the first side. The panel comprises a second grid disposed adjacent the second side. The first cap and the second cap and the first grid and the second grid defining a frame which envelopes and holds the core without piercing through the core.

The present invention pertains to an overcast for a mine. The overcast comprises sidewalls. The overcast comprises decking disposed on the sidewalls. The decking and sidewalls formed of at least one panel comprising a core having a top, a bottom, a first side and a second side. The panel comprises a first cap disposed on the top. The panel comprises a second cap disposed on the bottom. The panel comprises a first grid disposed adjacent the first side, the first cap and the second cap and the first grid and the second grid defining a frame which envelopes and holds the core without piercing through the core. The panel comprises mortar or concrete disposed on the first grid.

The present invention pertains to a stopping for a tunnel. The stopping comprises a plurality of panels. At least two of the panels are connected together. At least one panel comprises a core having a top, a bottom, a first side and a second side. The one panel comprises a first cap disposed on the top. The one panel comprises a second cap disposed on the bottom. The one panel comprises a first grid disposed adjacent the first side. The first cap and the second cap and the first grid and the second grid define a frame which envelopes and holds the core without piercing through the core. The one panel comprises mortar or concrete disposed on the first grid.

The present invention pertains to a method for building a wall. The method comprises the steps of placing a first panel in a desired position. The first panel comprises a core having a top, a bottom, a first side and a second side. The first panel comprises a first cap disposed on the top. The first panel comprises a second cap disposed on the bottom. The first panel comprises a first grid disposed adjacent the first side. The first cap and the second cap and the first grid and the second grid define a frame which envelopes and holds the core without piercing through the core. There is the step of placing a second panel adjacent the first panel. There is the step of connecting the first panel with the second panel. There is the step of applying mortar or concrete to the first panel and second panel.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawings, the preferred embodiment of the invention and preferred methods of practicing the invention are illustrated in which:

FIG. 1 shows a frame of the panel of the present invention.

FIG. 2 shows the panel.

FIG. 3 shows a portion of the first cap with the first and second grids and first and second bars.

FIG. 4 shows a top view of the portion of the first cap.

FIG. 5 shows a side view of the portion of the first cap.

FIG. 6 shows a portion of the first cap.

FIG. 7 shows a clamp and spacer.

FIG. 8 shows the clamp and spacer with the clamp unbent.

FIG. 9 shows a representation of a stopping.

FIG. 10 shows an exploded view of a representation of an overcast.

FIG. 11 is a side view of a representation of an overcast.

FIG. 12 is a side view of a representation of an overcast.

FIG. 13 is an overhead cutaway view of a representation of a mine with an overcast and a stopping.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein like reference numerals refer to similar or identical parts throughout the several views, and more specifically to FIGS. 1 and 2 thereof, there is shown a panel 10. The panel 10 comprises a core 12 having a top 14, a bottom 16, a first side 18 and a second side 20. The panel 10 comprises a first cap 22 disposed on the top 14. The panel 10 comprises a second cap 24 disposed on the bottom 16. The panel 10 comprises a first grid 26 disposed adjacent the first side 18. The panel 10 comprises a second grid 28 disposed adjacent the second side 20. The first cap 22 and the second cap 24 and the first grid 26 and the second grid 28 define a frame 34 which envelopes and holds the core 12 without piercing entirely through the core 12. The one panel 10 comprises mortar or concrete 83 disposed on the first grid 26.

The panel 10 may include a plurality of first bars 30, for example pieces of rebar, disposed adjacent the first side 18. The panel 10 may include a plurality of second bars 32, for example pieces of rebar, disposed adjacent the second side 20. The first cap 22 and the second cap 24 and the first grid 26 and the second grid 28 and if present, the first bars 30 and the second bars 32, define a frame 34 which envelopes and holds the core 12 without piercing through the core 12.

The first grid 26 may be attached to the first cap 22 and the second cap 24. The second grid 28 may be attached to the first cap 22 and the second cap 24. The first bars 30 may be attached to the first cap 22 and the second cap 24. The second bars 32 may be attached to the first cap 22 and the second cap 24. The first cap 22 may have c shaped cross section defined by a top web 36 and a top first flange 38 and a top second flange 40, with the top web 36 disposed on the top 14 of the core 12, as shown in FIGS. 2 and 3. The top first flange 38 is disposed on the first side 18, and the top second flange 40 is disposed on the second side 20.

The second cap 24 may have a c shaped cross section defined by a bottom web 42 and a bottom first flange 44 and a bottom second flange 46, with the bottom web 42 disposed on the top 14 of the core 12. The bottom first flange 44 is disposed on the first side 18, and the bottom second flange 46 is disposed on the second side 20. Each first bar may be attached to the top first flange 38 and the bottom first flange 44. Each second bar may be attached to the top second flange 40 and the bottom second flange 46. The panel 10 may include mortar or concrete disposed on the first grid 26 and on the second grid 28 to a thickness of about 1.5 inches or more.

The present invention pertains to an overcast 70 for a mine, as shown in FIGS. 10-13. The overcast 70 comprises sidewalls 71. The overcast comprises decking 73 disposed on the sidewalls 71. The decking 73 and sidewalls 71 formed of at least one panel At least one panel 10 comprises a core 12 having a top 14, a bottom 16, a first side 18 and a second side 20. The panel 10 comprises a first cap 22 disposed on the top 14. The panel 10 comprises a second cap 24 disposed on the bottom 16. The panel 10 comprises a first grid 26 disposed adjacent the first side 18. The panel 10 comprises a second grid 28 disposed adjacent the second side 20. The first cap 22 and the second cap 24 and the first grid 26 and the second grid 28 define a frame 34 which envelopes and holds the core 12 without piercing entirely through the core 12. The one panel 10 comprises mortar or concrete 83 disposed on the first grid 26.

The present invention pertains to a stopping 69 for a tunnel, as shown in FIG. 9. The stopping 69 comprises a plurality of panels 10. At least two of the panels 10 are connected together. At least one panel 10 comprises a core 12 having a top 14, a bottom 16, a first side 18 and a second side 20. The panel 10 comprises a first cap 22 disposed on the top 14. The panel 10 comprises a second cap 24 disposed on the bottom 16. The panel 10 comprises a first grid 26 disposed adjacent the first side 18. The panel 10 comprises a second grid 28 disposed adjacent the second side 20. The first cap 22 and the second cap 24 and the first grid 26 and the second grid 28 define a frame 34 which envelopes and holds the core 12 without piercing entirely through the core 12. The one panel 10 comprises mortar or concrete 83 disposed on the first grid 26.

The present invention pertains to a method for building a wall. The method comprises the steps of placing a first panel 10 in a desired position. The first panel 10 comprises a core 12 having a top 14, a bottom 16, a first side 18 and a second side 20. The panel 10 comprises a first cap 22 disposed on the top 14. The panel 10 comprises a second cap 24 disposed on the bottom 16. The panel 10 comprises a first grid 26 disposed adjacent the first side 18. The panel 10 comprises a second grid 28 disposed adjacent the second side 20. The first cap 22 and the second cap 24 and the first grid 26 and the second grid 28 define a frame 34 which envelopes and holds the core 12 without piercing entirely through the core 12. There is the step of placing a second panel adjacent the first panel 10. There is the step of connecting the first panel 10 with the second panel. There is the step of applying mortar or concrete to the first panel and second panel.

In the operation of the invention, the panel 10 is formed by placing the first cap 22 on the top 14 of the core 12 and the second cap 24 on the bottom 16 of the core 12. Each cap is 20 feet long, the web of the cap is 4.75 inches wide, and each flange is 2 inches wide. Each cap is made of 18 gauge steel. The first grid 26 is then placed on the first side 18 of the core 12 by having the top 14 of the first grid 26 inserted into raised slots 48 on the top first flange 38 at intervals along its length. Clamps 50 are then screwed down into the top first flange 38 at intervals along its length to hold the top 14 of the first grid 26 in place. Alternatively, the top 14 of the first grid 26 can be welded or braised or soldered to the top first flange 38 of the first cap 22. Each grid is formed of welded wire mesh made of 11 gauge steel, where the mesh is 2 inch by 2 inch. The core 12 is a 2.5 inch or 4 inch thick expanded polystyrene foam as per ASTM C578, incorporated by reference herein, and which has a flame spread index of 25 or less. The core 12 made of EPS is an insulation core 12. The length of the panel 10 is about 20 feet long and 4 feet high.

The bottom 16 of the first grid 26 is then inserted into raised slots 48 on the bottom first flange 44 at intervals along its length. The slots 48 facilitate the proper positioning and alignment of the grid. Clamps 50 are then screwed down into the bottom first flange 44 at intervals along its length to hold the bottom 16 of the first grid 26 in place. Alternatively, the bottom 16 of the first grid 26 can be welded or braised or soldered to the bottom first flange 44 of the first cap 22. The second grid 28 is then placed on the second side 20 of the core 12 in the same manner as the first grid 26 is placed on the first side 18.

Spacers 52, as shown in FIG. 5, with the clamps 50 are positioned at intervals on the top first and second flanges and bottom first and second flanges along their length to maintain a gap 56 between the grids and the respective surfaces of the core 12 for the cement to properly form on the core 12 and grids, as shown in FIG. 2. Each clamp 50 has a c portion 54 of metal that defines a clamp opening 58 through which a grid wire 60 of the top row of grid wires 60 of the first grid 26 extends, as shown in FIGS. 4 and 5. The c portion 54 is a rectangular strip of metal about 2 inches long and about 0.5 inches wide and 0.125 inches thick. The c portion 54 is formed by basically being bent in half. A bottom 16 of the c portion 54 is defined by a first leg 62 and a second leg 64 through which a screw 66 extends to capture the grid wire 60 in the clamp opening 58 when the screw 66 is tightened down onto the top first flange 38, as shown in FIGS. 5, 7 and 8. There is a metal spacer 52, in the form of a block or cylinder that is about 0.5 inches long and about 0.25 inches in diameter disposed between the clamp 50 and the top first flange 38. The screw 66 extends through a spacer 52 hole and the first and second legs 62, 64 and the top first flange 38 to hold the first grid 26 and clamp 50 and spacer 52 in place. The screw 66 is long enough to also penetrate about an inch into the core 12 when tightened down. This assembly is repeated at several locations along the top first flange 38, the top second flange 40, the bottom first flange 44 and the bottom second flange 46 to secure the first grid 26 at the desired distance from the first side 18 of the core 12, and the second grid 28 at the desired distance from the second side 20 of the core 12. The first grid 26 and second grid 28 serve to hold the mortar or concrete that is placed on the panel 10. Typically, concrete in the form of Gunite or Shotcrete is sprayed onto each side of the panel 10, as is well-known in the art.

The top 14 of each piece of rebar on the first side 18 is welded or braised to or inserted through a flange hole 68 in the top first flange 38, as shown in FIGS. 1, 2 and 6, and the bottom 16 of each piece of rebar on the first side 18 is also welded or braised to or inserted through a flange hole 68 in the bottom first flange 44. Similarly, the top 14 of each piece of rebar on the second side 20 is welded or braised to or inserted through the top second flange 40, and the bottom 16 of each piece of rebar on the second side 20 is welded or braised to or inserted through the bottom second flange 46. Each piece of rebar is tied or coupled to the grid at several locations along the piece of rebar's length with ties 72. The pieces of rebar serve to add structural strength, rigidity and integrity to the panel 10 so the panel 10 can withstand the loads typically expected to be placed on it. The pieces of rebar also serve the dual purpose of being a spacer 52 between the grid and the core 12 to maintain the gap 56 between the grid and the core 12 for the Gunite to better build up a cement layer. The rebar has a ⅜ inch diameter and is about 4 feet 1 inch long. A piece of rebar is typically spaced every three to four feet along the length of the panel. The rebar is typically used when the panel is used for decking in an overcast. In a stopping, or side wall and wing wall of an overcast, when the panel is vertically oriented relative to the ground, the rebar does not have to be used.

The panel 10 may be used for any type of building or construction applications. Underground, in a tunnel, such as that found in a mine, the panel 10 can be used for ventilation structures that include stoppings, overcasts, undercasts and even seals.

In the construction of a stopping 69, as shown in FIG. 9, the site in the mine would first be prepared, as is well-known in the art. A first panel 10 is placed alongside a seam extending essentially perpendicular from the seam across the tunnel. Holes are drilled in the floor alongside the panel 10. Resin capsules are inserted into the holes and then pieces of rebar are inserted into the holes which extend from the ground. Each piece of rebar is then tied to the grid to which it is alongside. In similar fashion, if the panel 10 placed on the ground does not extend entirely across the tunnel to the seam on the opposite side, a second panel 100, or at least a portion of a second panel 100 is placed alongside the first panel 10 already placed on the ground to extend across the tunnel between the opposing seams. The first grid 26 on the first panel 10 and the first grid 26 of the second panel 100 are coupled together either with ties 72 or couples to link the first panel 10 to the second panel 100. If the width of the tunnel is less than the length of a single panel 10, then the single panel 10 is cut to length to essentially extend across the tunnel between the opposing seams.

Depending on the height of the tunnel, additional panels may need to be placed on top of the first panel 10 and the second panel 100, if there is one. In similar fashion, if a third panel 200 is necessary to close the area of the tunnel above the first panel 10, the third panel 200 is placed on top of the first panel 10 and the first grid 26 of the first panel 10 and the first grid 26 of the third panel 200 are coupled with couplers or ties 72. Similarly, if a fourth panel 300, or a portion of a fourth panel 300 is needed to be placed on any second panel 100, then the fourth panel 300 is coupled in similar manner to the third panel 200 alongside it and the second panel 100 below it.

Once the width of the tunnel is essentially closed off, if it is so desired, holes are drilled into the roof of the tunnel alongside the front of the third panel 200 and fourth panel 300, if they are present, or just the first panel 10 if it is the only panel. Resin capsules can be inserted into the holes and pieces of rebar then inserted into the holes so they extend from the roof. The pieces of rebar extending from the roof are then tied or coupled to the first grid 26 to which they are alongside. In similar fashion the second side 20 of the stopping 69 formed of the first panel 10 and any additional panels are connected to rebar extending from the floor alongside the second side 20, and if desired from rebar extending from the ceiling. In addition, as explained in regard to the first side 18, the second grid 28 of each panel 10 is coupled together. Gunite is then sprayed on each side of the panels so a layer of at least 1.5 inches, and typically 2 inches, are formed on either side of the panels that make up the stopping 69. The Gunite is also applied along the edges of the panels alongside the seams so any openings or aps between the sides of the panels or panel, are closed off and create a seal, preventing any airflow past the stopping. The application of Gunite is well-known in the art.

In a similar manner an overcast 70, or undercast can be formed in an intersection of tunnels, for instance in a mine. See FIGS. 10-13. The sidewalls 71 are formed in the same way as described above for the stopping 69. The decking 73 of the overcast 70 is formed by placing panels flat alongside each other horizontally across the width of the tunnel with their sides disposed on top of the sidewalls 71 and supported by the sidewalls 71. The panels alongside each other form the decking 73 are tied or coupled together through their respective grids, first grid to first grid and second grid to second grid.

If one or more wing walls 75 are needed to close off air flow around the side walls 71, the wing walls 75 are built the same way as the walls for stopping, with the wing wall 75 built high enough to reach the seam. Pieces of rebar may be inserted into holes drilled into the seam with resin capsules to hold the rebar. The wing wall 75 can be tied to the rebar pieces. The sidewalls 71 and decking 73 and any wing walls 75 and gaps between them and the seams are sprayed with Gunite to a thickness of at least 1.5 inches and preferably 2 inches, to form an air tight seal and solid support structure that can withstand loads and forces of at least 15 psi.

Although the invention has been described in detail in the foregoing embodiments for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be described by the following claims.

Claims

1. A panel comprising:

a core having a top, a bottom, a first side and a second side;

a first cap disposed on the top;

a second cap disposed on the bottom;

a first grid disposed adjacent the first side; and

a second grid disposed adjacent the first side, the first cap and the second cap and the first grid and the second grid defining a frame which envelopes and holds the core without piercing through the core.

2. The panel of claim 1 wherein the first grid is attached to the first cap and the second cap.

3. The panel of claim 2 wherein the second grid is attached to the first cap and the second cap.

4. The panel of claim 3 wherein the first cap has a c shaped cross section defined by a top web and a top first flange and a top second flange, with the top web disposed on the top of the core, the top first flange disposed on the first side, and the top second flange disposed on the second side.

5. The panel of claim 4 wherein the second cap has a c shaped cross section defined by a bottom web and a bottom first flange and a bottom second flange, with the bottom web disposed on the top of the core, the bottom first flange disposed on the first side, and the bottom second flange disposed on the second side.

6. The panel of claim 5 including mortar or concrete disposed on the first grid.

7. The panel of claim 6 including a plurality of first bars disposed adjacent the first side; and a plurality of second bars disposed adjacent the second side, the first cap and the second cap and the first grid and the second grid and the first bars and the second bars defining a frame which envelopes and holds the core without piercing through the core.

8. The panel of claim 7 wherein the first bars are attached to the first cap and the second cap.

9. The panel of claim 8 wherein the second bars are attached to the first cap and the second cap.

10. The panel of claim 9 wherein each first bar is attached to the top first flange and the bottom first flange.

11. The panel of claim 10 wherein each second bar is attached to the top second flange and the bottom second flange.

12. An overcast for a miner comprising:

sidewalls;

decking disposed on the sidewalls, the decking and sidewalls formed of at least one panel comprising:

a core having a top, a bottom, a first side and a second side;

a first cap disposed on the top;

a second cap disposed on the bottom;

a first grid disposed adjacent the first side, the first cap and the second cap and the first grid and the second grid defining a frame which envelopes and holds the core without piercing through the core; and

mortar or concrete disposed on the first grid.

13. A stopping for a tunnel comprising:

a plurality of panels, at least two panels are connected together, at least one panel comprising:

a core having a top, a bottom, a first side and a second side;

a first cap disposed on the top;

a second cap disposed on the bottom;

a first grid disposed adjacent the first side, the first cap and the second cap and the first grid and the second grid defining a frame which envelopes and holds the core without piercing through the core; and

mortar or concrete disposed on the first grid.

14. A method for building a wall comprising the steps of:

placing a first panel in a desired position, the first panel comprising a core having a top, a bottom, a first side and a second side; a first cap disposed on the top; a second cap disposed on the bottom; a first grid disposed adjacent the first side; and a second grid disposed adjacent the first side, the first cap and the second cap and the first grid and the second grid defining a frame which envelopes and holds the core without piercing through the core;

placing a second panel adjacent the first panel;

connecting the first panel with the second panel; and

applying mortar or concrete to the first panel and second panel.