CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application Ser. No. 62/781,264, filed Dec. 18, 2018.
TECHNICAL FIELD The present disclosure generally relates to polymer lining systems, and more specifically, to a polymer lining system for vertical shafts such as those used in mining sites for air ventilation.
BACKGROUND Most of the shafts constructed today are circular in cross-section and lined with concrete. The concrete lining provides protection from weathering for the wall rock. The smooth passage of liner is beneficial for ventilation air and the concrete liner also provides structural integrity for the tunnel and permits ground water control. Current operations in constructing and lining shafts are time consuming, labor intensive, and expensive. In such operation, various types of wood and metal forms are typically lowered into place below the last-lined portion of the shaft and anchored into place followed by filling in concrete in the void space between the forms and the wall rock. The transport of heavy material such as metal forms down the shaft can present safety issues to the workers. In addition, frequently much time is lost waiting for the concrete to cure and strengthen before the forms may be stripped and removed out of the way and followed by repeating the drilling and construction process at a lower elevation. As can be perceived, such operation can be extremely time-consuming and expensive. Precast concrete or steel liners has also been used in drilled shaft stabilization; however, heavy rigging equipment is needed to transport such liners into position. In addition, such liners are susceptible to corrosion over time. Furthermore, such precast liners typically has a thick wall that reduce the effective internal diameter of the shaft and thus reducing air ventilation efficiency.
Accordingly, there is a need for improved vertical shaft lining systems which provide swift installation, enhanced worker safety, better durability and ventilation efficiency.
SUMMARY The present disclosure meets this need by providing a lightweight, thinner walled, modular fiber-reinforced polymer (FRP) liner system with a reduction in traditional rigging and suspended loads. As will be discussed subsequently, the assembled panel system may comprise arcuate panels that are made of fiber reinforced composite. These fiber reinforced composite liner systems may provide many unique benefits that enable their quick assembly into the liner during installation. Such unique elements may include, but are not limited to a smooth inner diameter surface and a ribbed outer diameter surface: a smooth inner surface (facing away from shaft wall) allows smooth air movement for ventilation; a ribbed outer surface (facing towards the shaft wall) provides additional hoop strength and buckling strength to withstand the hydrostatic load of uncured grout during grout filling operations. The present embodiments may also help to accommodate stress concentration at the holes for anchoring bolt. In addition, the undulation of the ribbed pattern also helps to provide mechanical interlocking mechanism to secure the liner to the grout.
According to a first aspect, a liner system, including a plurality of arcuate panels vertically interlocked, each arcuate panel comprising fiber reinforced composite. Each arcuate panel includes a first engagement tab disposed at a first edge of a panel frame, a second engagement tab disposed at a second edge of the panel frame, the second edge arranged opposite the first edge,
a third engagement tab disposed on a third edge of the panel frame, and a fourth engagement tab disposed on a fourth edge of the panel frame, the fourth edge arranged opposite the third edge. A first engagement tab of a first arcuate panel engages a second engagement tab of a second arcuate panel vertically aligned with the first arcuate panel. A second engagement tab of the first arcuate panel engages a first engagement tab of a third arcuate panel vertically aligned with the first arcuate panel. A third engagement tab of the first arcuate panel engages a fourth engagement tab of a fourth arcuate panel horizontally aligned with the first arcuate panel. A fourth engagement tab of the first arcuate panel engages a third engagement tab of a fifth arcuate panel horizontally aligned with the first arcuate panel and opposite the fourth arcuate panel.
According to any of the previous aspects, the second engagement tab of each arcuate panel includes a securement portion fixedly secured to the arcuate panel, an extension portion connected to the securement portion; and an enclosure portion connected to the extension portion.
According to any of the previous aspects, the extension portion extends radially outward from the arcuate panel, forming a receptacle with the enclosure portion.
According to any of the previous aspects, the extension portion is integral with the securement portion and the enclosure portion.
According to any of the previous aspects, the receptacle of the second engagement tab of the first arcuate panel is operatively arranged to receive the first engagement tab of the third arcuate panel.
According to any of the previous aspects, a shape of the receptacle corresponds to a shape of the first engagement tab of the third arcuate panel.
According to any of the previous aspects, the first engagement tab is radially offset from the arcuate panel.
According to any of the previous aspects, the first engagement tab extends vertically above the top edge of the panel frame.
According to any of the previous aspects, the second engagement tab of each arcuate panel includes an offset portion fixedly secured to the arcuate panel and an enclosure portion connected to the offset portion.
According to any of the previous aspects, the offset portion radially offsets the enclosure portion from the arcuate panel, forming a receptacle with the enclosure portion.
According to any of the previous aspects, the receptacle of the second engagement tab of the first arcuate panel is operatively arranged to receive the first engagement tab of the third arcuate panel.
According to any of the previous aspects, the first engagement tab of the first arcuate panel engages with at least two panels arranged above the first panel.
According to any of the previous aspects, the first engagement tab of the first arcuate panel includes a first portion and a second portion.
According to any of the previous aspects, the first portion and the second portion of the first engagement tab of a first arcuate panel engage with different panels arranged above the first arcuate panel.
According to any of the previous aspects, the third engagement tab of each arcuate panel comprises an enclosure portion connected to the arcuate panel, wherein the enclosure portion extends radially outward from the arcuate panel, forming a receptacle with the arcuate panel.
According to any of the previous aspects, the fourth engagement tab of each arcuate panel is radially offset from the arcuate panel.
According to any of the previous aspects, the receptacle of the third engagement tab of the first arcuate panel is operatively arranged to receive the fourth engagement tab of the fourth arcuate panel.
According to any of the previous aspects, the fiber reinforced composite comprises glass fibers, aramid fibers, carbon fibers, basalt fibers, or combinations thereof.
According to any of the previous aspects, the fiber reinforced composite comprises polymer resin selected from polyester resin, vinyl ester resin, phenolic resin, polyurethane resin, epoxy resin, and combinations thereof. The polymer resin may further comprise additives that improve flame resistance, reduce smoke generation during fire to be meet any fire, smoke, and toxicity (FST) requirements for underground operation. Examples of FST requirements include those derived from MDG 3608—“Non-metallic materials for use in underground coal mines” published by Mine Safety Operations Branch, a division of the New South Wales Government. Examples of applicable ASTM standards include ASTM E84 and UL94 for Flame Resistance, and ASTM E84 and E662 for smoke generation.
According to any of the previous aspects, the plurality of arcuate panels are vertically interlocked to form a cylindrical liner.
According to any of the previous aspects, the cylindrical liner is arranged within a vertical shaft.
According to any of the previous aspects, the cylindrical liner is secured within the vertical shaft via a filler arranged between the cylindrical liner and an inner wall of the vertical shaft.
According to any of the previous aspects, at least one arcuate panel of the cylindrical liner further comprises a scribe to retain the filler between the cylindrical liner and the inner wall of the vertical shaft.
According to a second aspect, a method of lining a vertical shaft, includes arranging a first plurality of arcuate panels within the vertical shaft, wherein the arcuate panels interlock to form a first ring of a cylindrical liner, arranging a filler between the first ring and an inner wall of the vertical shaft, and curing the filler arranged between the first ring and the inner wall of the vertical shaft, where the cured filler secures the first ring within the vertical shaft.
According to any of the previous aspects, arranging a plurality of arcuate panels within the vertical shaft further includes arranging a second plurality of arcuate panels within the vertical shaft, wherein the arcuate panels interlock to form a second ring of the cylindrical liner and interlocking the first ring with the second ring in the vertical direction prior to arranging the filler between the first ring, second ring, and an inner wall of the vertical shaft, forming the cylindrical liner.
According to any of the previous aspects, the first plurality of arcuate panels forming the first ring each include a scribe to retain the filler between the cylindrical liner and the inner wall of the vertical shaft.
According to any of the previous aspects, a seal is arranged on the scribe to retain the filler between the cylindrical liner and the inner wall of the vertical shaft.
These and additional features provided by the embodiments described herein will be more fully understood in view of the following detailed description, in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS The embodiments set forth in the drawings are illustrative and exemplary in nature and not intended to limit the subject matter defined by the claims. The following detailed description of the illustrative embodiments can be understood when read in conjunction with the following drawings, where like structure is indicated with like reference numerals and in which:
FIG. 1A schematically depicts an embodiment of an arcuate panel, according to one or more embodiments shown or described herein;
FIG. 1B schematically depicts a cylindrical liner formed from the arcuate panels of FIG. 1A, according to one or more embodiments shown or described herein;
FIG. 1C schematically depicts a cross-section of the cylindrical liner of FIG. 1B, according to one or more embodiments shown or described herein;
FIG. 1D schematically depicts a cross-section of the cylindrical liner of FIG. 1B, according to one or more embodiments shown or described herein;
FIG. 1E schematically depicts a cross-section of the cylindrical liner of FIG. 1B, according to one or more embodiments shown or described herein;
FIG. 2A schematically depicts an embodiment of an arcuate panel, according to one or more embodiments shown or described herein;
FIG. 2B schematically depicts an a cylindrical liner formed from the arcuate panels of FIG. 2A, according to one or more embodiments shown or described herein;
FIG. 2C schematically depicts a cross-section of the cylindrical liner of FIG. 2B, according to one or more embodiments shown or described herein;
FIG. 2D schematically depicts a cross-section of the cylindrical liner of FIG. 2B, according to one or more embodiments shown or described herein;
FIG. 2E schematically depicts a cross-section of the cylindrical liner of FIG. 2B, according to one or more embodiments shown or described herein;
FIG. 3A schematically depicts an embodiment of an arcuate panel, according to one or more embodiments shown or described herein;
FIG. 3B schematically depicts an a cylindrical liner formed from the arcuate panels of FIG. 3A, according to one or more embodiments shown or described herein;
FIG. 3C schematically depicts a cross-section of the cylindrical liner of FIG. 3B, according to one or more embodiments shown or described herein;
FIG. 3D schematically depicts a cross-section of the cylindrical liner of FIG. 3B, according to one or more embodiments shown or described herein;
FIG. 3E schematically depicts a cross-section of the cylindrical liner of FIG. 3B, according to one or more embodiments shown or described herein;
FIG. 4A schematically depicts an embodiment of an arcuate panel, according to one or more embodiments shown or described herein;
FIG. 4B schematically depicts an a cylindrical liner formed from the arcuate panels of FIG. 4A, according to one or more embodiments shown or described herein;
FIG. 4C schematically depicts a cross-section of the cylindrical liner of FIG. 4B, according to one or more embodiments shown or described herein;
FIG. 4D schematically depicts a cross-section of the cylindrical liner of FIG. 4B, according to one or more embodiments shown or described herein;
FIG. 4E schematically depicts a cross-section of the cylindrical liner of FIG. 4B, according to one or more embodiments shown or described herein;
FIG. 5 schematically depicts an embodiment of an arcuate panel, according to one or more embodiments shown or described herein;
FIG. 6 schematically depicts the arcuate panel of FIG. 5 arranged within a vertical shaft according to one or more embodiments shown or described herein;
FIG. 7 schematically depicts the arcuate panel of FIG. 5 arranged within a vertical shaft according to one or more embodiments shown or described herein; and
FIG. 8 depicts a method of lining a vertical shaft, according to one or more embodiments shown or described herein.
DETAILED DESCRIPTION The liner system generally includes a plurality of arcuate panels vertically interlocked, each arcuate panel comprising fiber reinforced composite. Each arcuate panel includes a first engagement tab disposed at a first edge of a panel frame, a second engagement tab disposed at a second edge of the panel frame, the second edge arranged opposite the first edge, a third engagement tab disposed on a third edge of the panel frame, and a fourth engagement tab disposed on a fourth edge of the panel frame, the fourth edge arranged opposite the third edge. Various embodiments of the liner system will be described in greater detail herein.
Referring now to FIG. 1A, an embodiment of a panel assembly 100 is generally depicted. As illustrated, the panel assembly 100 generally includes a panel 102 and engagement tabs 104A, 104B, 106, 108, and 110 arranged at various locations on the panel 102. The panel 102 includes a first edge 102A, a second edge 102B arranged opposite the first edge 102A, a third edge 102C, and a fourth edge 102D arranged opposite the third edge 102C and adjacent to the first edge 102A and the second edge 102B. The engagement tabs 104A, 104B are arranged on the first edge 102A of the panel 102. The engagement tab 106 is arranged on the second edge 102B of the panel 102. The engagement tab 108 is arranged on the third edge 102C of the panel 102. The engagement tab 110 is arranged on the fourth edge 102D of the panel 102. The engagement tabs 104A, 104B, 106, 108, and 110 may be integral with the panel 102, or may be additional components which are secured to the panel through mechanical or adhesive means, such as bolts or glue. The panel 102 and the engagement tabs 104A, 104B, 106, 108, and 110 may be made from a fiber reinforced composite, such as glass fibers, aramid fibers, carbon fibers, basalt fibers, or combinations thereof. Additionally, the fiber reinforced composite which the panel 102 is made of may include a polymer resin selected from polyester resin, vinyl ester resin, phenolic resin, polyurethane resin, epoxy resin, and combinations thereof. The polymer resin may further comprise additives that improve flame resistance, reduce smoke generation during fire, or both to meet any applicable fire, smoke, and toxicity (FST) requirements for underground operation.
Referring now to FIG. 1B, a plurality of panels 102 may be interlocked in order to form a cylindrical liner. The cylindrical liner may be formed from multiple rings formed from the panels 102 interlocked vertically with one another. In order to form a ring, a plurality of panels 102 may be horizontally secured together via the engagement tabs 108 and 110, which is described in greater detail below. As depicted, the engagement tabs 104A, 104B of a panel 102 engage with the engagement tab 106 of a panel 102 arranged vertically above the lower panel 102. Additionally, in embodiments, the engagement tab 104A may engage with an engagement tab 106 of a different panel 102 that the engagement tab 104B engages with, creating an offset alignment between vertically aligned rings of panels 102.
Referring now to FIG. 1C, the engagement tab 108 and the engagement tab 110 may be a male and female configuration, where the engagement tab 108 fits within the engagement tab 110. The engagement tab may include an insertion portion 112 and a tip portion 114. The tip portion 114 may be tapered to aid and guide in insertion of the insertion portion 112 with the engagement tab 110 during assembly of the liner panels. Additionally, the engagement tab 108 may include an offset potion 118 which radially offsets the engagement tab 108 from the panel 102. The engagement tab 110 may include an enclosure portion 116 which creates an insertion space 120 with the panel 102. The enclosure portion 116 is arranged on the surface 102E of the panel 102. The insertion space 120 may be formed to have the same profile as the insertion portion 112 and tip portion 114 of the engagement tab 108, or may have a profile which is slightly wider than the insertion portion 112 to allow ease of installation.
Referring now to FIG. 1D, the engagement tabs 104A and 104B engage with the engagement tab 106 of a vertically aligned panel 102. The engagement tabs 104A, 104B each may include an extension portion 130 which extends vertically above the first edge 102A of the panel 102. The extension portion 130 may also be radially offset from the surface 102E of the panel 102. Additionally, the extension portion 130 may be tapered to allow for easier insertion. Due to the vertical and radial arrangement of the engagement tabs 104A, 104B, the first edge 102A of the lower panel 102 may abut against the second edge 102B of the upper panel 102. In embodiments, the engagement tab 106 may include a securement portion 122, an extension portion 124, and an enclosure portion 126. The securement portion 122 secures the engagement tab 106 to the panel 102. The extension portion 124 extends radially outward from the panel 102. The enclosure portion 126 creates a receptacle 128 with the panel 102 since the enclosure portion 126 is radially offset from the surface 102E due to the extension portion 124. When a first panel 102 is arranged vertically above another panel 102, and the first edge 102A of the lower panel 102 abuts the second edge 102B of the upper panel 102, the engagement tab 104A of the lower panel 102 will be arranged within the receptacle 128 of the upper panel 102, formed from the second engagement tab 106. The profile of the engagement tab 104A may be correspondingly shaped as the receptacle 128, or may have a profile which is slightly smaller than the receptacle 128 to allow ease of installation of a plurality of panels 102.
Referring now to FIG. 1E, as rings of panels 102 are formed to create a cylindrical liner, a bottom most ring of panels 102 may include a scribe 107 instead of a second engagement tab 106. The scribe 107 may include a securement portion 132, an extension portion 134, an enclosure portion 136, and a sealing portion 138. The securement portion 132 secures the scribe 107 to the panel 102. The extension portion 134 extends radially outward from the panel 102. The enclosure portion 136 may create a receptacle with the panel 102 since the enclosure portion 136 is radially offset from the surface 102E due to the extension portion 124. If a ring formed from the panels 102 has scribes 107, additional rings of panels 102 may be arranged underneath, with the engagement tabs 104A, 104B engaging with the scribe 107 and being inserted into the receptacle formed between the enclosure portion 136 and the panel 102. The sealing portion 138 may extend radially outward from the panel 102 toward an inner wall of a vertical chamber. The sealing portion 138 is provided to allow for a mounting point for a sealing member to encapsulate a filler arranged between the inner wall of a vertical shaft and the panels 102.
Referring now to FIG. 2A, an embodiment of a panel assembly 200 is generally depicted. As illustrated, the panel assembly 200 generally includes a panel 202 and engagement tabs 204A, 204B, 206, 208, and 210 arranged at various locations on the panel 202. The panel 202 includes a first edge 202A, a second edge 202B arranged opposite the first edge 202A, a third edge 202C, and a fourth edge 202D arranged opposite the third edge 202C and adjacent to the first edge 202A and the second edge 202B. The engagement tabs 204A, 204B are arranged on the first edge 202A of the panel 202. The engagement tab 206 is arranged on the second edge 202B of the panel 202. The engagement tab 208 is arranged on the third edge 202C of the panel 202. The engagement tab 210 is arranged on the fourth edge 202D of the panel 202. The engagement tabs 204A, 204B, 206, 208, and 210 may be integral with the panel 202, or may be additional components which are secured to the panel through mechanical or adhesive means, such as bolts or glue. The panel 102 and the engagement tabs 204A, 204B, 206, 208, and 210 may be made from a fiber reinforced composite, such as glass fibers, aramid fibers, carbon fibers, basalt fibers, or combinations thereof. Additionally, the fiber reinforced composite which the panel 202 is made of may include a polymer resin selected from polyester resin, vinyl ester resin, phenolic resin, polyurethane resin, epoxy resin, and combinations thereof. The polymer resin may further comprise additives that improve flame resistance, reduce smoke generation during fire to be meet any fire, smoke, and toxicity (FST) requirements for underground operation.
Referring now to FIG. 2B, a plurality of panels 202 may be interlocked in order to form a cylindrical liner. The cylindrical liner may be formed from multiple rings formed from the panels 202 interlocked vertically with one another. In order to form a ring, a plurality of panels 202 may be horizontally secured together via the engagement tabs 208 and 210, which is described in greater detail below. As depicted, the engagement tabs 204A, 204B of a panel 202 engage with the engagement tab 206 of a panel 202 arranged vertically above the lower panel 202. Additionally, in embodiments, the engagement tab 204A may engage with an engagement tab 206 of a different panel 202 that the engagement tab 204B engages with, creating an offset alignment between vertically aligned rings of panels 202.
Referring now to FIG. 2C, the engagement tab 208 and the engagement tab 210 may be a male and female configuration, where the engagement tab 208 fits within the engagement tab 210. The engagement tab may include an insertion portion 212 and a tip portion 214. The tip portion 214 may be tapered to aid in insertion of the insertion portion 212 with the engagement tab 210. Additionally, the engagement tab 208 may include an offset potion 218 which radially offsets the engagement tab 208 from the panel 202. The engagement tab 210 may include an enclosure portion 216 which creates an insertion space 220 with the panel 202. The enclosure portion 216 is arranged on the surface 202E of the panel 202. The insertion space 220 may be formed to have the same profile as the insertion portion 212 and tip portion 214 of the engagement tab 208, or may have a profile which is slightly wider than the insertion portion 212 to allow ease of installation.
Referring now to FIG. 2D, the engagement tabs 204A and 204B engage with the engagement tab 206 of a vertically aligned panel 202. The engagement tabs 204A, 204B each may include an extension portion 230 which extends vertically above the first edge 202A of the panel 202. The extension portion 230 may also be radially offset from the surface 202E of the panel 202. Additionally, the extension portion 230 may be tapered to allow for easier insertion. Due to the vertical and radial arrangement of the engagement tabs 204A and 204B, the first edge 202A of the lower panel 202 may abut against the second edge 202B of the upper panel 202. In embodiments, the engagement tab 206 may include a securement portion 222, an extension portion 224, and an enclosure portion 226. The securement portion 222 secures the extension portion 224 and enclosure portion 226 to the panel 102. The securement portion 222 may be arranged in a layered configuration with the extension portion 224 in order to radially offset the extension portion 224 and the enclosure portion 226 from the panel 202. The securement portion 222 and the enclosure portion 226 create a receptacle 228 with the panel 202 since the enclosure portion 226 is radially offset from the surface 202E. When a first panel 202 is arranged vertically above another panel 202, and the first edge 202A of the lower panel 202 abuts the second edge 202B of the upper panel 202, the engagement tab 204A of the lower panel 202 will be arranged within the receptacle 228 of the upper panel 202, formed from the second engagement tab 206. The profile of the engagement tab 204A may be correspondingly shaped as the receptacle 228, or may have a profile which is slightly smaller than the receptacle 228 to allow ease of installation of a plurality of panels 202.
Referring now to FIG. 2E, as rings of panels 202 are formed to create a cylindrical liner, a bottom most ring of panels 202 may include a scribe 207 instead of a second engagement tab 206. The scribe 207 may include a securement portion 232, an extension portion 234, an enclosure portion 236, and a sealing portion 238. The securement portion 232 secures the scribe 207 to the panel 202. The securement portion 232 secures the extension portion 234 and enclosure portion 236 to the panel 202. The securement portion 232 may be arranged in a layered configuration with the extension portion 234 in order to radially offset the extension portion 234 and the enclosure portion 236 from the panel 202. The enclosure portion 236 may create a receptacle with the panel 202. If a ring formed from the panels 202 has scribes 207, additional rings of panels 202 may be arranged underneath, with the engagement tabs 204A, 204B engaging with the scribe 207 and being inserted into the receptacle formed between the enclosure portion 236 and the panel 202. The sealing portion 238 may extend radially outward from the panel 202 toward an inner wall of a vertical chamber. The sealing portion 238 is provided to allow for a mounting point for a sealing member to encapsulate a filler arranged between the inner wall of a vertical shaft and the panels 202.
Referring now to FIG. 3A, an embodiment of a panel assembly 300 is generally depicted. As illustrated, the panel assembly 300 generally includes a panel 302 and engagement tabs 304, 306, 308, and 310 arranged at various locations on the panel 302. The panel 302 includes a first edge 302A, a second edge 302B arranged opposite the first edge 302A, a third edge 302C, and a fourth edge 302D arranged opposite the third edge 302C and adjacent to the first edge 302A and the second edge 302B. The engagement tab 304 is arranged on the first edge 302A of the panel 302. The engagement tab 306 is arranged on the second edge 302B of the panel 302. The engagement tab 308 is arranged on the third edge 302C of the panel 302. The engagement tab 310 is arranged on the fourth edge 302D of the panel 302. The engagement tabs 304, 306, 308, and 310 may be integral with the panel 302, or may be additional components which are secured to the panel through mechanical or adhesive means, such as bolts or glue. The panel 302 and the engagement tabs 304, 306, 308, and 310 may be made from a fiber reinforced composite, such as glass fibers, aramid fibers, carbon fibers, basalt fibers, or combinations thereof. Additionally, the fiber reinforced composite which the panel 102 is made of may include a polymer resin selected from polyester resin, vinyl ester resin, phenolic resin, polyurethane resin, epoxy resin, and combinations thereof. The polymer resin may further comprise additives that improve flame resistance, reduce smoke generation during fire, or both to meet any applicable fire, smoke, and toxicity (FST) requirements for underground operation.
Referring now to FIG. 3B, a plurality of panels 302 may be interlocked in order to form a cylindrical liner. The cylindrical liner may be formed from multiple rings formed from the panels 302 interlocked vertically with one another. In order to form a ring, a plurality of panels 302 may be horizontally secured together via the engagement tabs 308 and 310, which is described in greater detail below. As depicted, the engagement tabs 304 of a panel 302 engage with the engagement tab 306 of a panel 302 arranged vertically above the lower panel 302. Additionally, in embodiments, the engagement tab 304 may engage with multiple engagement tabs 306 of different panels 302, creating an offset alignment between vertically aligned rings of panels 302.
Referring now to FIG. 3C, the engagement tab 308 and the engagement tab 310 may be a male and female configuration, where the engagement tab 308 fits within the engagement tab 310. The engagement tab 308 may include a securement portion 316 and an enclosure portion 318. The securement portion 316 secures the enclosure portion 318 to the panel 302. The securement portion 316 may be arranged in a layered configuration with the enclosure portion 318 in order to radially offset the enclosure portion 318 from the panel 302. The securement portion 316 and the enclosure portion 316 create a receptacle 320 with the panel 302 since the enclosure portion 316 is radially offset from the surface 302E. When a first panel 302 is arranged adjacent to another panel 302, and the third edge 302C of the adjacent panel 302 abuts the fourth edge 302D of the upper panel 302, the engagement tab 308 of the adjacent panel 302 will be arranged within the receptacle 320 of the panel 302, formed from the engagement tab 310. The profile of the engagement tab 308 may be correspondingly shaped as the receptacle 320, or may have a profile which is slightly smaller than the receptacle 320 to allow ease of installation of a plurality of panels 302.
Referring now to FIG. 3D, the engagement tab 304 engages with the engagement tab 306 of a vertically aligned panel 302. The engagement tab 304 may include an extension portion 330 which extends vertically above the first edge 302A of the panel 302. The extension portion 330 may also be radially offset from the surface 302E of the panel 302. Additionally, the extension portion 330 may be tapered to allow for easier insertion. Due to the vertical and radial arrangement of the engagement tab 304, the first edge 302A of the lower panel 302 may abut against the second edge 302B of the upper panel 302. In embodiments, the engagement tab 306 may include a securement portion 322, an extension portion 324, and an enclosure portion 326. The securement portion 322 secures the extension portion 324 and enclosure portion 326 to the panel 302. The securement portion 322 may be arranged in a layered configuration with the extension portion 324 in order to radially offset the extension portion 324 and the enclosure portion 326 from the panel 302. The securement portion 322 and the enclosure portion 326 create a receptacle 328 with the panel 302 since the enclosure portion 326 is radially offset from the surface 302E. When a first panel 302 is arranged vertically above another panel 302, and the first edge 302A of the lower panel 302 abuts the second edge 302B of the upper panel 302, the engagement tab 304 of the lower panel 302 will be arranged within the receptacle 328 of the upper panel 302, formed from the second engagement tab 306. The profile of the engagement tab 304 may be correspondingly shaped as the receptacle 328, or may have a profile which is slightly smaller than the receptacle 328 to allow ease of installation of a plurality of panels 302.
Referring now to FIG. 3E, as rings of panels 302 are formed to create a cylindrical liner, a bottom most ring of panels 302 may include a scribe 307 instead of a second engagement tab 306. The scribe 307 may include a securement portion 332, an extension portion 334, an enclosure portion 336, and a sealing portion 338. The securement portion 332 secures the scribe 307 to the panel 302. The securement portion 332 secures the extension portion 334 and enclosure portion 336 to the panel 302. The securement portion 332 may be arranged in a layered configuration with the extension portion 334 in order to radially offset the extension portion 334 and the enclosure portion 336 from the panel 302. The enclosure portion 336 may create a receptacle with the panel 302. If a ring formed from the panels 302 has scribes 307, additional rings of panels 302 may be arranged underneath, with the engagement tab 304 engaging with the scribe 307 and being inserted into the receptacle formed between the enclosure portion 336 and the panel 302. The sealing portion 338 may extend radially outward from the panel 302 toward an inner wall of a vertical chamber. The sealing portion 338 is provided to allow for a mounting point for a sealing member to encapsulate a filler arranged between the inner wall of a vertical shaft and the panels 302.
Referring now to FIG. 4A, an embodiment of a panel assembly 400 is generally depicted. As illustrated, the panel assembly 400 generally includes a panel 402 and engagement tabs 404, 406, 408, and 410 arranged at various locations on the panel 402. The panel 402 includes a first edge 402A, a second edge 402B arranged opposite the first edge 402A, a third edge 402C, and a fourth edge 402D arranged opposite the third edge 402C and adjacent to the first edge 402A and the second edge 402B. The engagement tab 404 is arranged on the first edge 402A of the panel 402. The engagement tab 406 is arranged on the second edge 402B of the panel 402. The engagement tab 408 is arranged on the third edge 402C of the panel 402. The engagement tab 410 is arranged on the fourth edge 402D of the panel 402. The engagement tabs 404, 406, 408, and 410 may be integral with the panel 402, or may be additional components which are secured to the panel through mechanical or adhesive means, such as bolts or glue. The panel 402 and the engagement tabs 404, 406, 408, and 410 may be made from a fiber reinforced composite, such as glass fibers, aramid fibers, carbon fibers, basalt fibers, or combinations thereof. Additionally, the fiber reinforced composite which the panel 402 is made of may include a polymer resin selected from polyester resin, vinyl ester resin, phenolic resin, polyurethane resin, epoxy resin, and combinations thereof. The polymer resin may further comprise additives that improve flame resistance, reduce smoke generation during fire, or both to meet any applicable fire, smoke, and toxicity (FST) requirements for underground operation.
Referring now to FIG. 4B, a plurality of panels 402 may be interlocked in order to form a cylindrical liner. The cylindrical liner may be formed from multiple rings formed from the panels 402 interlocked vertically with one another. In order to form a ring, a plurality of panels 402 may be horizontally secured together via the engagement tabs 408 and 410, which is described in greater detail below. As depicted, the engagement tabs 404 of a panel 402 engage with the engagement tab 406 of a panel 402 arranged vertically above the lower panel 402. Additionally, in embodiments, the engagement tab 404 may engage with multiple engagement tabs 406 of different panels 402, creating an offset alignment between vertically aligned rings of panels 402.
Referring now to FIG. 4C, the engagement tab 408 and the engagement tab 410 may be a male and female configuration, where the engagement tab 408 fits within the engagement tab 410. The engagement tab 408 may include an insertion portion 412 and a tip portion 414. The tip portion 414 may be tapered to aid in insertion of the insertion portion 412 with the engagement tab 410. Additionally, the engagement tab 408 may include an offset potion 418 which radially offsets the engagement tab 408 from the panel 402. The engagement tab 410 may include an enclosure portion 416 which creates an insertion space 420 with the panel 402. The enclosure portion 416 is arranged on the surface 402E of the panel 402. The insertion space 420 may be formed to have the same profile as the insertion portion 412 and tip portion 414 of the engagement tab 408, or may have a profile which is slightly wider than the insertion portion 412 to allow ease of installation. In embodiments, the enclosure portion 416 may be integral with the panel 402.
Referring now to FIG. 4D, the engagement tab 404 engages with the engagement tab 406 of a vertically aligned panel 402. The engagement tab 404 may include an extension portion 430 which extends vertically above the first edge 402A of the panel 402. The extension portion 430 may also be radially offset from the surface 402E of the panel 402. Additionally, the extension portion 430 may be tapered to allow for easier insertion. Due to the vertical and radial arrangement of the engagement tab 404, the first edge 402A of the lower panel 402 may abut against the second edge 402B of the upper panel 402. In embodiments, the engagement tab 406 may include a securement portion 422, an extension portion 424, and an enclosure portion 426. The securement portion 422 secures the engagement tab 406 to the panel 402. The extension portion 424 extends radially outward from the panel 402. The enclosure portion 426 creates a receptacle 428 with the panel 402 since the enclosure portion 426 is radially offset from the surface 402E due to the extension portion 424. When a first panel 402 is arranged vertically above another panel 402, and the first edge 402A of the lower panel 402 abuts the second edge 402B of the upper panel 402, the engagement tab 404 of the lower panel 402 will be arranged within the receptacle 428 of the upper panel 402, formed from the engagement tab 406. The profile of the engagement tab 404 may be correspondingly shaped as the receptacle 428, or may have a profile which is slightly smaller than the receptacle 428 to allow ease of installation of a plurality of panels 402. In embodiments, the engagement tabs 404, 406, 408, and 410 may be integral with the panel 402.
Referring now to FIG. 4E, as rings of panels 402 are formed to create a cylindrical liner, a bottom most ring of panels 402 may include a scribe 407 instead of a second engagement tab 406. The scribe 407 may include a securement portion 432, an extension portion 434, an enclosure portion 436, and a sealing portion 438. The securement portion 432 secures the scribe 407 to the panel 402. The extension portion 434 extends radially outward from the panel 402. The enclosure portion 436 may create a receptacle with the panel 402 since the enclosure portion 436 is radially offset from the surface 402E due to the extension portion 424. If a ring formed from the panels 402 has scribes 407, additional rings of panels 402 may be arranged underneath, with the engagement tab 404 engaging with the scribe 407 and being inserted into the receptacle formed between the enclosure portion 436 and the panel 402. The sealing portion 438 may extend radially outward from the panel 402 toward an inner wall of a vertical chamber. The sealing portion 438 is provided to allow for a mounting point for a sealing member to encapsulate a filler arranged between the inner wall of a vertical shaft and the panels 402. In embodiments, the securement portion 432, extension portion 434, enclosure portion 436, and sealing portion 438 may be integral with the panel 402.
Referring now to FIG. 5, an embodiment of a panel assembly 500 is generally depicted. As illustrated, the panel assembly 500 generally includes a panel 502 and engagement tabs 504, 506, 508, and 510 arranged at various locations on the panel 502. The panel 502 includes a first edge 502A, a second edge 502B arranged opposite the first edge 502A, a third edge 502C, and a fourth edge 502D arranged opposite the third edge 502C and adjacent to the first edge 502A and the second edge 502B. The engagement tab 504 is arranged on the first edge 502A of the panel 502. The engagement tab 506 is arranged on the second edge 502B of the panel 502. The engagement tab 508 is arranged on the third edge 502C of the panel 402. The engagement tab 510 is arranged on the fourth edge 502D of the panel 502. The engagement tabs 504, 506, 508, and 510 may be integral with the panel 502, or may be additional components which are secured to the panel through mechanical or adhesive means, such as bolts or glue. The panel 502 and the engagement tabs 504, 506, 508, and 510 may be made from a fiber reinforced composite, such as glass fibers, aramid fibers, carbon fibers, basalt fibers, or combinations thereof. Additionally, the fiber reinforced composite which the panel 502 is made of may include a polymer resin selected from polyester resin, vinyl ester resin, phenolic resin, polyurethane resin, epoxy resin, and combinations thereof. The polymer resin may further comprise additives that improve flame resistance, reduce smoke generation during fire, or both to meet any applicable fire, smoke, and toxicity (FST) requirements for underground operation.
Referring still to FIG. 5, the panel 502 may include a filler port 512 and a plurality of anchor holes 514 arranged within the panel 502. The filler port may be an aperture extending fully though the panel 502 and allows for a filler, such as grout, cement, or cellular concrete, to be delivered via a slickline by pump, behind the panel 502 after the panel 502 is installed within a vertical shaft. The anchor holes 514 may be a plurality of apertures extending through the panel 502 which allow a securement means, such as a bolt, to secure the panel 502 to an inner wall of a vertical shaft. It should be appreciated that filler port 512 and anchor holes 512 may be arranged within panels 102, 202, 302, and 402 described above.
Referring now to FIG. 6, a plurality of panels 502 may be arranged within a vertical shaft 10 which has been pre-drilled to its desired depth. As the panels 502 are lowered and arranged within the vertical shaft 10, a plum bob 18 attached to a string 20 may be used for ensuring the panels 502 are leveled correctly. A leveling tab 22 may abut the panels 502 to ensure the panels 502 are parallel with the inner wall 11 of the vertical shaft 10. As the panels 502 are formed into rings within the vertical shaft 10, a spacing bolt 16 may be used to radially displace the panels 502 from the inner wall 11 of the vertical shaft 10 in order to form the space 12 between the panels 502 and the inner wall 11. The spacer bolt 16 may be arranged within an anchor hole 514, or may be secured to the surface 502F of the panel 502. Additionally, an anchor bolt 14 may be used to further secure the panels 502, which comprise a ring, within the vertical shaft 10. The anchor bolts 14 may be arranged within the anchor holes 514 of the panel 502, and extend into the inner wall 11 of the vertical shaft 10. As an alternative to secure the liner panel ring to the shaft wall by anchor bolts, after the spacer bolts 16 are in place, a wheeled travelling frame, shaped to a cylindrical profile matching the inner surface profile of the liner, may be used to apply a load pressing the liner against the shaft wall before cementitious fillers are pumped in.
Referring now to FIG. 7, after the plurality of panels 502 are arranged within the vertical shaft 10, and secured to the inner wall 11 forming a space 12 between the inner wall 11 and the panels 502, a sealing member 26 may be arranged on a scribe 507. The sealing member 26 may be an FRP ledge angle such as the sealing portion 438. The sealing member may further comprise rubber gasket to provide a better seal. As stated above, a scribe is used to encapsulate a filler arranged between the panels 502 and the inner wall 11 of the vertical shaft 10. The scribe 507 of panel 502 includes an extension portion 508 and a securement portion 509. The extension portion 508 allows for the sealing member 26 to be arranged above the scribe 507. Additionally in embodiments, the securement portion 509 may be secured directly to the inner wall 11 via anchor bolt 26. After the sealing member 26 is arranged on the scribe 507, a curb or plug layer may be formed on the sealing member 26 by introducing a layer of structural expanding polyurethane foam through a field drilled bleeder holes to seal any gap against the shaft wall. After the plug layer is cured, a filler 24 may be poured or pumped into the space 12 between the inner wall 11 and the panels 502. The filler 24 may be poured or pumped through the filler hole 512 of the panels 502. In embodiments, the filler 24 may be lightweight concrete blend, such as a foam concrete or lightweight cellular concrete, which will cure and permanently secure the panels 502 within the vertical shaft 10.
Referring now to the flow diagram of FIG. 8 in conjunction with FIGS. 1A-7, an illustrative method 800 of installing a linear system within a vertical shaft is schematically depicted. More specifically, the panels 102 are operable to be installed within a vertical shaft and secured to the inner wall of the vertical shaft. The depiction of FIG. 8 and the accompanying description below is not meant to limit the subject matter described herein or represent an exact description of how the panels are installed, but instead is meant to provide a simple schematic overview to illustrate the liner system characteristics of the method described herein.
Referring now to FIG. 8, in conjunction with panels 102 of FIGS. 1A-1E and 5-7, a flow diagram is schematically depicted of an illustrative method 800 of lining a vertical shaft. Initially, at step 802, a first plurality of arcuate panels may be arranged within the vertical shaft to form a first ring. Referring to FIGS. 1B and 6, the entire vertical shaft 10 may be predrilled prior to arranging any panels 102 within the vertical shaft 10. Installation of the liner system starts from the top of the vertical shaft 10, installing one layer/ring of panels 102 before moving to the next lower layer/ring. In embodiments, installation from the top of the vertical shaft 10 is for safety reasons to avoid debris falling onto an installation crew installing the panels 102 within the vertical shaft 10. In order to form a first ring, the panels 102 lowered into the shaft and are interlocked horizontally with one another along each panel's 102 respective engagement tabs 108 and engagement tabs 110. Since the panels 102 have a natural curve to them, as the panels 102 interlock along their engagement tabs 108 and engagement tabs 110, the panels 102 will create a first ring, where the engagement tab 108 of the last panel 102 will interlock with the engagement tab 110 of the first panel 102 of the first ring.
At step 804, a second plurality of arcuate panels may be lower into the shaft below the first ring formed in step 802 and attached to the bottom of the first ring to form a second ring within the vertical shaft. Referring to FIGS. 1B and 6, a second ring of panels 102 is interlocked horizontally along their respective engagement tabs 108 and engagement tabs 110 in order to form the second ring, similarly to the first ring of panels 102. In embodiments, the first and second ring of panels 102 may be formed within the vertical shaft 10, or may be assembled outside of the vertical shaft 10 and then lowered into the vertical shaft 10. Additionally, in embodiments, the second ring of panels 102 is arranged vertically below the first ring of panels 102.
At step 806, the first ring may be interlocked with the second ring in the vertical direction to form a cylindrical liner. Referring to FIGS. 1B and 6, the first ring of panels 102 and the second ring of panels 102 may be vertically arranged to one another. The first ring of panels 102 interlocks with the second ring of panels 102 along the engagement tab 106 of the first ring of panels 102 with the engagement tab 104 of the second ring of panels 102 when the first ring of panels 102 is arranged vertically above the second ring of panels 102. Additionally, in embodiments, the connection between the engagement tabs 108, 110 of the first ring of panels 102 may be horizontally offset with the connection between the engagement tabs 108, 110 of the second ring of panels 102.
At step 808, a filler may be arranged between the cylindrical liner and an inner wall of the vertical shaft. Referring to FIGS. 1B, 1E, and 7, after a certain number of rings of panels 102 have been stacked and vertically arranged within the vertical shaft 10, a bottom ring of panels 102 having scribes 107 instead of engagement tabs 110 are installed vertically below the rings of panels 102 currently within the vertical shaft 10. In embodiments, the rings of panels 102 may be temporarily secured (e.g. anchored) to the inner wall 11 of the vertical shaft 10 in order to form a gap 12 between the panels 102 forming the cylindrical liner and the inner wall 11 of the vertical shaft 10. Additionally, in embodiments, polyurethane plug or seal 26 may be arranged near the bottom of ring of panels 102 with the scribe 107. The seal 26 aids in keeping the filler 24 encapsulated between the panels 102 and the inner wall 11 of the vertical shaft 10 as the filler 24 cures or hardens to permanently secure the cylindrical liner within the vertical shaft 10. A lightweight grout/filler 24 may be pumped/poured into the space 12 from the top grout port 512 of each panel 102 in order to ensure no air gaps are formed. Gravity may be used to fill the space 12, starting from the bottom layer of panels 102 first and moving up to fill the space 12 behind the next layer of panels 102 until all space between the liner panels 102 and inner wall 11 is filled with filler 24.
At step 810, the filler arranged between the cylindrical liner and the inner wall of the vertical shaft may be cured. Referring to FIGS. 1B and 7, the filler 24 may cure or harden to permanently secure the cylindrical liner within the vertical shaft 10. In embodiments, steps 802-810 may be repeated numerous times in order to fully line the vertical shaft 10 with panels 102. Each section may include a plurality of panels 102 forming a plurality of rings, where the bottom ring of each section includes a scribe 107 to contain the filler 24 within the section.
Turning now to the specific compositions used in the fiber reinforced composite, various materials are contemplated for the fiber reinforcement and the polymer resin. In one or more embodiments, the fiber reinforcement may include stitched e-glass fabric, chopped e-glass mat or their combinations. Other types of fiber reinforcement architecture, such as random mats, scrims, chopped fibers, knits, unidirectional plies, three-dimensional weaves, three-dimensional fiber preforms, plain weave fabrics, twill fabrics, harness satin fabrics, or combinations thereof, are also contemplated.
Moreover, various embodiments are considered suitable for the polymer resin, for example, epoxy, bismaleimide, vinyl ester, polyester, acrylic cyanate ester, and combinations thereof. In one embodiment, the fiber reinforced polymer includes flame-retardant polyester resins and acrylic polymer resin. The polymer resin may further comprise additives that improve flame resistance, reduce smoke generation during fire, or both to meet any applicable fire, smoke, and toxicity (FST) requirements for underground operation.
Referring now to FIGS. 1A-7, the liner system may be defined by various mechanical properties. In various embodiments, the liner may have an ultimate tensile strength (hoop) measured according to ASTM D638 of at least 200 MPa (30,000 lb/in2), 200 to 600 MPa, or 200 to 400 MPa. In various embodiments, the liner may have an ultimate tensile strength (longitudinal) measured according to ASTM D638 of at least 200 MPa (30,000 lb/in2), 200 to 800 MPa, 200 to 600 MPa, or 200 to 400 MPa. In various embodiments, the liner may have a tensile modulus (hoop) measured according to ASTM D638 of at least 10,340 MPa (1,500,000 lb/in2), 10,340 to 70,000 MPa, 10,340 to 50,000 MPa, or 10,340 to 30,000 MPa. In various embodiments, the liner may have an ultimate flexural strength measured according to ASTM D790 of at least 200 MPa (30,000 lb/in2), 200 to 600 MPa, or 200 to 400 MPa. In various embodiments, the liner may have a flexural modulus measured according to ASTM D790 of at least 10,340 MPa (1,500,000 lb/in2), 10,340 to 70,000 MPa, 10,340 to 50,000 MPa, or 10,340 to 30,000 MPa. In various embodiments, the liner may have an ultimate short beam shear strength (in plane) measured according to ASTM D2344 of at least 51 MPa (7,500 lb/in2), 51 to 150 MPa, 51 to 125 MPa, or 51 to 100 MPa. In various embodiments, the liner may have a density measured according to ASTM D792 of at least 1,200 kg/m3 (75 lb/ft3), 1,200 to 3,000 kg/m3, 1,200 to 2,500 kg/m3, or 1,200 to 2,000 kg/m3.
It should now be understood that embodiments described herein are directed to a liner system, including a plurality of arcuate panels vertically interlocked, each arcuate panel comprising fiber reinforced composite. Each arcuate panel includes a first engagement tab disposed at a first edge of a panel frame, a second engagement tab disposed at a second edge of the panel frame, the second edge arranged opposite the first edge, a third engagement tab disposed on a third edge of the panel frame, and a fourth engagement tab disposed on a fourth edge of the panel frame, the fourth edge arranged opposite the third edge. The panels may be interlocked with one another along the third engagement tabs and fourth engagement tabs to form a plurality of rings. The plurality of rings may then be interlocked vertically with one another along the first engagement tabs and second engagement tabs to form a cylindrical liner within a vertical shaft.
The singular forms “a”, “an” and “the” include plural referents, unless the context clearly dictates otherwise.
It is further noted that spatially oriented terms like “top”, “bottom,” and similar are not utilized herein to limit the scope of the claimed invention or to imply that certain special orientations are critical, essential, or even important to the structure or function of the claimed invention. Rather, these terms are merely intended to provide relative positions of components in a commonly understood manner.
Throughout this disclosure ranges are provided. It is envisioned that each discrete value encompassed by the ranges are also included. Additionally, the ranges which may be formed by each discrete value encompassed by the explicitly disclosed ranges are equally envisioned.
As used in this disclosure and in the appended claims, the words “comprise,” “has,” and “include” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps.
It will be apparent to those skilled in the art that various modifications and variations can be made to the embodiments described herein without departing from the spirit and scope of the claimed subject matter. Thus, it is intended that the specification cover the modifications and variations of the various embodiments described herein provided such modification and variations come within the scope of the appended claims and their equivalents.
