Method for supporting a subsurface material

A support member for supporting a roof of a subsurface space. The support member may include a base portion for defining a surface area to contact a ceiling of the subsurface space. One or more sockets may extend from the base for defining openings for receiving roof bolts therethrough. Accordingly, the support member may be configured to function as a washer for the roof bolts to support the roof material above the ceiling. The sockets may include covers for preventing the roof bolts from extending out of the sockets. The sockets may be oriented at angles with respect to the base such that when roof bolts are placed in the sockets, the roof bolts may extend at angles with respect to each other in a splayed configuration.

CROSS-REFERENCE TO RELATED APPLICATIONS

Not Applicable.

Not Applicable.

BACKGROUND

1. The Field of the Invention

The present disclosure relates generally to support devices used for subsurface materials, and more particularly, but not necessarily entirely, to devices, sometimes referred to as roof plates, for receiving roof bolts to assist in preventing roofs of underground mines from caving in.

2. Description of Related Art

It is common practice in the mining industry to support underground mine roofs with support members to prevent roof cave-ins. One method of supporting underground mine roofs includes attaching lower levels rock strata to upper layers of rock using roof bolts. Roof bolts may vary in length and diameter, but may typically be sized one-half inch or more in diameter and 30 inches to 12 feet or more in length. Other varieties of roof bolts, such as cable bolts, may be 10 to 24 feet in length, for example. The roof bolts may be formed as rigid members such as rebar or threaded rod bolts, or the roof bolts may be formed as multi-strand cable bolts. Holes may be drilled in the ceiling of a mine and the roof bolts may be inserted to tie the rock strata in the ceiling with upper layers of rock.

Some embodiments of roof bolts may also include use of epoxy or polyester resins and various types of cement. After a hole is placed in the mine ceiling, an epoxy or polyester resin in a pliable plastic tube may be inserted in the hole. Next, a roof bolt may be inserted in the hole which may tear the packaging for the epoxy or polyester resin and allow the resin to mix and spread to the surrounding rock layers. The resin may set up or harden within a matter of seconds to thereby seal the bolt to the rock layers. Cements are much slower in setting and are, therefore, used where setting time is not critical.

A support member, commonly referred to as a bearing plate or a roof bolt plate, may be placed on the mine ceiling and held in place by a head or nut on the roof bolt. In cases where a threaded nut is used, it is tightened to bring the roof bolt plate snugly against the mine ceiling. The plate thereby functions as a washer to prevent the roof bolt from being drawn into the bolt hole in the ceiling of the mine. The roof bolts may be spaced at specified intervals along the mine ceiling, such as every four feet, for example, to provide adequate support to the mine roof. Accordingly, cave-ins in the mine may be prevented and the mine may be safely accessed.

Despite the advantages of the known roof bolt plate systems, improvements are still being sought. For example, roof bolts are known to break, thereby causing a portion of the bolt to be ejected from the ceiling causing a safety hazard. Attempts have been made to prevent the roof bolts from shooting out of the ceiling and causing a safety hazard. For example, a wire mesh, such as a chain link material and/or a rubber matting material, may be place over the ceiling to hold the roof bolts in the ceiling in the event the roof bolts are broken. However, the cost of materials and labor required to install wire mesh and rubber matting may be high.

Also, when a roof bolt breaks, a replacement roof bolt will usually have to be installed in close proximity to the broken bolt. This may add to the cost and time required to stabilize a roof. Additionally, the number of locations suitable for the roof bolt plates may be limited. Moreover, the loads supportable by the known roof bolt plate systems may be limited such that the prior art roof bolt plates may not be suitable in some situations. For example, the known roof bolt plate systems may not be effective in supporting soft or plastic soils.

The prior art is thus characterized by several disadvantages that are addressed by the present disclosure. The present disclosure minimizes, and in some aspects eliminates, the above-mentioned failures, and other problems, by utilizing the methods and structural features described herein.

The features and advantages of the disclosure will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by the practice of the disclosure without undue experimentation. The features and advantages of the disclosure may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims.

DETAILED DESCRIPTION

It must be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Moreover, in describing and claiming the present disclosure, the following terminology will be used in accordance with the definitions set out below.

As referred to herein, the term “subsurface” shall be construed broadly to include areas or volumes beneath or beyond a surface, including but not limited to the surface of the earth and surfaces of manufactured structures, such that the subsurface may extend upwardly, downwardly or laterally beyond the surface.

The term “space” as used herein shall be construed broadly to include an extent or expanse of a surface or three-dimensional area, including but not limited to the expanse defining a mine, tunnel, channel, chamber, passage, cavern, cave, or above ground feature, for example.

As used herein, the term “ceiling” shall be construed broadly to include an interior surface defining a space.

The term “roof” as used herein, shall be construed broadly to include material extending beyond a ceiling in a direction towards an exterior of a space.

Referring now toFIG. 1, a schematic cross-sectional view is shown of a space or tunnel10formed in a subsurface material12. The tunnel10may form part of an underground mine, or the tunnel10may form part of any other subsurface space known to those skilled in the art. Accordingly, the tunnel10may be formed in any manner known to those skilled in the art in any suitable shape and size. The subsurface material12may include any variety of material suitable for forming a tunnel, such as rock or earthen material for example.

The tunnel10may include a material surface, or ceiling14defining an interior surface of the tunnel10. Also, a roof16may be formed in the subsurface material12beyond the ceiling14. It will be understood that although the ceiling14is depicted at the top of the tunnel10as shown inFIG. 1, the present disclosure may be applicable to the sides and bottom of the tunnel10as well. Accordingly, the ceiling14and roof16need not necessarily be in the top of the tunnel10as shown.

Roof bolts18may be placed in the subsurface material12to support the roof16by attaching lower levels of subsurface material12, such as rock strata, to upper levels of subsurface material12. The roof bolts18may vary in length and diameter, and may typically be sized one-half inch or more in diameter and 30 inches to 24 feet or more in length. The roof bolts18may be formed as rigid members such as rebar or threaded rod bolts, or the roof bolts18may be formed as multi-strand cable bolts, or the roof bolts18may be formed in any other suitable manner known to those skilled in the art.

Holes20may be drilled in the subsurface material12through the ceiling14of the tunnel10, and the roof bolts18may be inserted into the holes20to tie the subsurface material12together and thereby support the roof16.

As discussed above, some embodiments of roof bolts18may also include use of epoxy resins. After the hole20is formed in the roof16, an epoxy or polyester resin in a pliable plastic tube may be inserted in the hole20. Next, a roof bolt18may be inserted in the hole20which may tear the packaging for the epoxy resin and allow the resin to mix and spread to the surrounding rock layers in the subsurface material12. In some embodiments, a drilling machine may be used to spin the roof bolt18for a period of time, such as approximately 10 seconds for example, to mix the resin. The bolt may then be held for a period of time, such as 5 seconds for example. The resin may set up or harden within a matter of seconds to thereby seal the roof bolt18to the subsurface material12.

A bearing plate22or roof bolt plate, may be placed on the mine ceiling14and held in place by a head24or nut on the roof bolt18. In cases where a threaded nut is used, it can be tightened thus bringing the bearing plate22snugly against the mine ceiling14, to thereby spread the load of the roof bolt18over a large enough area of the ceiling14to function as a washer to prevent the roof bolt18from being drawn into the bolt hole20in the ceiling14of the tunnel10. Typical bearing plates may be approximately 6 inches square, for example, and may form a node for receiving the roof bolt18. The roof bolts18may be spaced at specified intervals along the mine ceiling14, such as every four feet, for example, to provide adequate support to the mine roof16. Accordingly, cave-ins in the tunnel10may be prevented and the tunnel10may be safely accessed.

Referring toFIG. 2, the tunnel10is shown similar to the depiction ofFIG. 1, except that support members26, also referred to as roof bolt plates, or fixtures, are shown in accordance with the principles of the present disclosure. It will be appreciated thatFIG. 2contains many of the same features as those represented inFIG. 1, and only the new or different features will be discussed to most succinctly explain the embodiment of the disclosure illustrated inFIG. 2. One or more of the support members26may be positioned on the ceiling14of the tunnel10for receiving one or more roof bolts18. Accordingly, each support member26may form a node on the ceiling for receiving one or more roof bolts18.

A rear perspective view of one embodiment of a support member, indicated generally at26, is shown inFIG. 3. The support member26may include a base28for defining a surface for contacting the ceiling14of the tunnel10. The base28may be formed in various different shapes, sizes and thicknesses and may be formed of materials known in the art to provide suitable strength and durability characteristics. One embodiment of the base28may include a central portion30that may be substantially planar. The base28may include one or more extensions32surrounding the central portion30. The extensions32may be rounded lobes or the extensions may be formed in other configurations within the scope of the present disclosure.

The base28may also include one or more fastener openings34for receiving a fastener (not shown) for fastening the support member26to the ceiling14of the tunnel10. The fastener may include a bolt that may be relatively short as compared to the roof bolts18, such as two to four feet in length, for example. This feature allows the installer to fix the support member26to the ceiling14before the holes20are drilled into the roof16for the roof bolts18. The fastener openings34may be located in the central portion30, or the fastener openings34may be positioned at other suitable locations on the support member26. It will be understood that various quantities of fastener openings34may be provided on the support member26, or alternatively, some embodiments of the support member26may not include any fastener openings. As shown inFIG. 3, one embodiment of the present disclosure may include a single fastener opening having a diameter of between ¾ to one inch, for example. It will be understood, however, that the fastener opening34may be formed in various different sizes and configurations within the scope of the present disclosure.

The support member26may also include one or more sockets36extending from the base28. Each of the sockets36may define an opening38for receiving a roof bolt18therethrough for supporting the roof16of the tunnel10. The sockets36may be formed of a sidewall40having an interior surface42defining the opening38, and an exterior surface44. One embodiment of the socket36may be formed as a short piece of pipe fixedly joined to the base28. It will be understood that the phrase “extending from” as referred to herein, such as a socket36“extending from” the base28, shall be understood to mean that the socket28runs, projects or reaches beyond the base28, such that the socket36may not be formed as merely an opening in the base28itself. Rather, the sidewall40defining the socket36may project beyond the base28. It will also be understood that alternative embodiments of the present disclosure may include a socket that may be formed integral and coextensive with the base28such that the socket may not extend from the base28.

A cover46may be placed on the socket36to prevent a roof bolt18from exiting the socket36. One embodiment of the socket36may include threads on the exterior surface44such that the cover46may be threadably engaged with the socket36to maintain the cover46on the socket36. It will be understood that the cover46may be attached to the socket36using other attachment mechanisms known in the art, such that the cover46may be removably attachable to the socket36. Alternative embodiments of the present disclosure may include covers that may be permanently attached to the socket36.

As shown most clearly inFIG. 4, the cover46may extend over an entire end of the socket36. However, it will be understood that the cover46may have various different configurations, and may include one or more openings such that the interior of the socket36may be accessible, at least in part, even if the cover46is attached to the socket36. Moreover, as shown inFIG. 4a,the covers46may be removed from the sockets36to access an interior of the sockets36.

Referring toFIG. 5, a plan view of the support member26is shown. A side cross-sectional view of the support member26, taken along line A-A inFIG. 5, is shown inFIG. 6. In one embodiment, the sockets36may be joined to the base28by a weld49. However, it will be understood that various different methods and structures known in the art may be used to join the socket36to the base28. Moreover, in one embodiment, the sockets36may be integrally formed with the base28such that the support member26is a one-piece, unitary member. Alternatively, the sockets36may be removably joined to the base28.

One embodiment of the support member26may be formed such that the extensions32may project at an angle with respect to the central portion30. For example, the extensions32may project at an angle48that may be greater than 0 degrees, and less than 25 degrees. One embodiment may include extensions32that may project at an angle48of approximately 5 degrees with respect to the central portion30. It will be understood, however, that the extensions32may project at various other angles within the scope of the present disclosure, and some embodiments of the extensions32may be co-planar with respect to the central portion30. It will be appreciated that the support member26may be manufactured with the extensions32oriented at a pre-determined position so as to facilitate installation of the roof bolts18. Moreover, the quality of the installation of the roof bolts18may be more easily controlled to maintain the maximum strength achievable by the support member26.

The angled extensions32may allow the roof bolts18to be directed in a non-parallel direction such that an end of the roof bolts18furthest from the support member26may be spaced further apart than the head of the roof bolts18in the support member, to thereby form a splayed configuration, as shown most clearly inFIG. 2. Accordingly, the support member26may be configured to receive the roof bolts18in a splayed manner in which the heads of the roof bolts18may converge and be in close proximity to each other, whereas the ends of the roof bolts18may diverge and be spaced further apart. For example, one embodiment of the present disclosure may allow the heads of the roof bolts18to be spaced apart by approximately four inches, whereas the ends of the roof bolts18furthest from the support member26may be spaced apart by approximately four feet. This technique may be used to spread the stress that the roof bolts18place on the upper strata of the roof16over a larger area, thereby greatly increasing the potential force that the roof bolts18can place on the roof16. Accordingly, more than a single roof bolt18may be positioned in a support member26to enhance the support provided by the support member26into the subsurface material12forming the tunnel10.

It will be understood that the embodiment of the support member26depicted inFIGS. 3-5may include four sockets36for receiving up to four roof bolts18to provide enhanced support capabilities of the support member26. It will be understood, however, that other number of sockets36may be provided on the support member26, and that roof bolts18need not be placed in each of the sockets36. For example, the support member26having four sockets36may allow roof bolts18to be installed at different time intervals. Two roof bolts18may be installed initially, and if one or both of the roof bolts18fail, additional roof bolts18may be installed in the remaining sockets36without removing or replacing the support member26. Accordingly, the configuration of the support member26may allow for versatile use.

As shown inFIG. 6, the interior surface42of the socket36may be counter bored to define a seat or stop50for abutting with a head24of the roof bolts18for limiting movement of the roof bolts18into the socket36. Moreover, the stop50may provide a surface area for transferring a force from the roof bolts18to the support member26, such that a tensile force from the roof bolts18may be transferred to the base28and into the ceiling14of the tunnel10.

Referring toFIG. 7, a break-away cross sectional view is shown of a support member26having a roof bolt18installed in the socket36, and a cover46attached to the socket36. An indicator52may be utilized to show if the roof bolt18has broken. Roof bolts18are commonly subjected to significant loads. For example, some roof bolts18may have a breaking strength of approximately 60,000 pounds, such that if the roof bolt18is subjected to an excessive force, the roof bolt18may break. When a roof bolt18breaks, high tensile forces acting on the roof bolt18may cause the roof bolt18to shoot out of the hole20. Roof bolts may thereby create a safety risk, or the roof bolts may cause damage to items within the tunnel10if not properly constrained.

The indicator52may be formed as a pin or rollpin positioned in a hole in the cover46. One embodiment of the indicator may be located in a center of the cover46. After the roof bolt18has been installed through the socket36, and the cover46has been placed on the socket36, the pin may be tapped against the head of the roof bolt18. Accordingly, if the roof bolt18breaks, the pin may be pushed to an extended position where it may serve as a visual indicator that the roof bolt18has broken. Removal of the cover46at this point may be a dangerous procedure without additional safety precautions. It will be understood that the indicator52may be formed in various different configurations within the scope of the present disclosure. For example, some embodiments of the indicator52may be removable from the cover46, whereas other embodiments of the indicator52may be provided with a mechanism to prevent the indicator52from separating from the cover46.

One exemplary embodiment of the support member26may include a base28formed of a half inch thick plate material. Four sockets36may be spaced approximately 4.5 inches apart from center to center in a substantially square configuration. The sockets36may be welded to the extensions32, and the extensions32may be sized approximately 4.5 inches in diameter. The sockets36may be formed having a 2 inch inner diameter, and a 2.25 inch inner diameter counter bore to form the stop50. The central portion30of the base28may be configured to be substantially planar and approximately 3.18 inches square. The extensions32may project at an angle of approximately 5 degrees from the central portion30. It will be appreciated, however, that the support member26may be formed in various other configurations and dimensions within the scope of the present disclosure, and the above described embodiment is for illustrative purposes only.

It will be understood that one feature of the present disclosure is that the support member26may form a guide for installation of the roof bolts18. For example, once the support member26is attached to the ceiling14with a fastener through the fastener opening34, a drill bit may be inserted through the sockets36to guide the drill bit in forming the hole20in the subsurface material12. The sockets36may also be extended by coupling a pipe on an end of the socket36to provide additional support for a drill bit if desired. For example, a standard pipe, about 18 inches long, may be coupled to the threads on the exterior of the sockets36to thereby extend the length of the sockets36to facilitate guiding a drill bit into the subsurface material12for forming the holes20.

Once the holes20have been formed in the subsurface material12, the roof bolts18may be installed through the sockets36in a manner known to those skilled in the art. It will be understood, however, that in some embodiments, the holes20may be formed as the roof bolts18are installed. After the roof bolts18are installed through the sockets36, covers46may be placed over the sockets36to maintain the roof bolts18within the sockets36. The roof bolts18may pull the support member26against the ceiling14and provide support to the subsurface material12.

It will be understood that the support member26may be utilized to provide an economical manner of securing soft or weak strata in the subsurface material12above the tunnel10, such that material may be safely mined in areas that may otherwise not be economical to mine. Also, the support member26may be used to greatly enhance personal safety in the tunnel10. The support member26may utilize a relatively simple design, and the support member26may be manufactured from known, readily accessible materials having suitable strength and durability characteristics. Moreover, the support member26may be manufactured using known procedures such that the support members26may be produced at a reasonable cost. Accordingly, the potential benefit of the support members26in terms of economical recovery of materials from a mine is great in comparison to the cost of the support members26.

It will also be understood that the principles of the present disclosure may be used in above-ground, or surface uses. For example, the support members26may be useful in stabilizing slopes along roadways or near structures, or in surface mining applications. Accordingly, the principles of the present disclosure are not restricted to underground mines or tunnels.

Reference will now be made toFIG. 8to describe an alternative embodiment of the present disclosure. As previously discussed, the presently disclosed embodiments of the disclosure illustrated herein are merely exemplary of the possible embodiments of the disclosure, including that illustrated inFIG. 8.

It will be appreciated that the alternative embodiment of the disclosure illustrated inFIG. 8contains many of the same structures represented inFIGS. 1-7and only the new or different structures will be explained to most succinctly explain the features which come with the embodiments of the disclosure illustrated inFIG. 8.

FIG. 8illustrates a plan view of an alternative embodiment support member, indicated generally at26a.The alternative embodiment support member26amay include a base28a.The base28amay be circular in shape, or the base28amay have any other suitable shape within the scope of the present disclosure. Accordingly, the base28amay be formed without discrete lobes as disclosed in the previous embodiments. Rather, the base28amay include a single extension32a.The base28amay include a central portion30ahaving a fastener opening34a.The extension32amay extend at an angle with respect to the central portion30asimilar to the embodiments previously discussed. Moreover, the alternative embodiment support member26amay have a plurality of sockets36a,such as six sockets36a,for example, for receiving roof bolts18. It will also be understood that the alternative embodiment support member26amay have other quantities of sockets36awithin the scope of the present disclosure. It will be understood that the alternative embodiment support member26amay be used in a manner similar to the previously discussed embodiments.

Referring now toFIGS. 9A-9D, side views are shown of alternative embodiments of the socket, indicated at36b-36e,respectively. InFIG. 9A, the socket36bmay include a pin opening54for receiving a socket pin56. The socket pin56may be inserted in the pin opening54to prevent the roof bolt18from exiting the socket36b.The socket pin56may be held in place in the socket36bby a cotter pin58or any other suitable clip or fastener known to those skilled in the art. Accordingly, the socket pin56may block passage of the roof bolt18through the socket36b,while allowing the roof bolt18to be viewed through an end of the socket36b.

As shown inFIG. 9B, an additional alternative embodiment socket36cmay include fastener openings58for receiving fasteners60, such as screws or bolts. A cover46amay be provided with corresponding openings62, such that the cover46amay be placed on the socket36c,and the corresponding openings62in the cover46amay be aligned with the fastener openings58. Fasteners60may then be inserted to fasten the cover46ato the socket36c.It will be understood that any number of fastener openings58and fasteners60may be used to attach the cover46ato the socket36cwithin the scope of the present disclosure.

Referring toFIG. 9C, an additional alternative embodiment socket36dand cover46bis shown. It will be understood that the embodiment shown inFIG. 9Cmay include many of the features of the embodiments previously discussed. As shown inFIG. 9C, the cover46bmay have a different shape, including a smaller dimensioned height, having rounded corners. It will be understood that the cover46bmay have various other configurations within the scope of the present disclosure.

As shown inFIG. 9D, an additional alternative socket36emay include internal threads64, and the cover46cmay have corresponding external threads66. The cover46cmay also include a driving surface68, for joining with a tool for rotating the cover46c.The driving surface68may have various different configurations known in the art, such as polygonal shaped exterior surfaces, or various different shaped recesses, for joining with a driving tool. Accordingly, the cover46cmay be rotated into the socket36eto thereby cover the socket36e.

Reference will now to made toFIG. 10to describe an additional alternative embodiment of the present disclosure. As previously discussed, the presently disclosed embodiments of the disclosure illustrated herein are merely exemplary of the possible embodiments of the disclosure, including that illustrated inFIG. 10.

It will be appreciated that the alternative embodiment of the disclosure illustrated inFIG. 10contains many of the same structures represented inFIGS. 1-9and only the new or different structures will be explained to most succinctly explain the features which come with the embodiments of the disclosure illustrated inFIG. 10.

FIG. 10shows a perspective view of an alternative embodiment support member, indicated generally at26b.The support member26bmay be formed in a substantial triangular configuration having three extensions32fand three sockets36f.It will be understood that a plan view of the support member26bis shown inFIG. 11, and a side cross-sectional view of the support member26b,taken along line A-A inFIG. 11, is shown inFIG. 12.

Similarly, referring toFIGS. 13-15, another alternative embodiment support member26cis shown. It will be appreciated that the alternative embodiment of the disclosure illustrated inFIGS. 13-15contains many of the same structures represented inFIGS. 1-12and only the new or different structures will be explained to most succinctly explain the features which come with the embodiments of the disclosure illustrated inFIGS. 13-15.

The support member26cmay be formed having five extensions32gand five sockets36g.It will be understood that a perspective view of the support member26cis shown inFIG. 13, whereas a plan view of the support member26cis shown inFIG. 14, and a side cross-sectional view of the support member26c,taken along line A-A inFIG. 14, is shown inFIG. 15.

Reference will now to made toFIG. 16to describe an additional alternative embodiment of the present disclosure. As previously discussed, the presently disclosed embodiments of the disclosure illustrated herein are merely exemplary of the possible embodiments of the disclosure, including that illustrated inFIG. 16.

It will be appreciated that the alternative embodiment of the disclosure illustrated inFIG. 16contains many of the same structures represented inFIGS. 1-15and only the new or different structures will be explained to most succinctly explain the features which come with the embodiments of the disclosure illustrated inFIG. 16.

FIG. 16shows a perspective view of an alternative embodiment support member, indicated generally at70. The support member70may include a base28hhaving sockets36hand a rotatable cover72supported on a post74. Once the roof bolts18have been installed, the cover72may be rotated about the post74, as best shown in the plan view of the support member70shown inFIG. 17, such that the cover openings76are not in alignment with the sockets36hto thereby block the roof bolts18from exiting the sockets36h.

One embodiment of the support member70may also include slots77for receiving fasteners or bolts (not shown) for attaching the support member70to the ceiling14to hold the support member70in place while the roof bolts18are installed. The slots77may function similar to the fastener opening34in previously disclosed embodiments. It will be understood that the fasteners used in the slots77to attach the support member70to the ceiling14may have any suitable size, such as two feet in length, for example. In some embodiments, the fasteners in the slots77may be used as a temporary holding mechanism to hold the support member70to the ceiling14until the roof bolts18are installed, whereas in other embodiments, the fasteners in the slots77may be left in place in the ceiling14permanently. It will be understood, however, that the quantity, size, configuration and position of the slots77may vary as desired within the scope of the present disclosure. Accordingly, some embodiments may include slots77in only the base28h,and other embodiments may have more slots77in the base than in the rotatable cover72, or more slots in the rotatable cover72than in the base28h.

As shown most clearly inFIG. 18, which shows a side cross-sectional view of the support member70taken along line A-A inFIG. 17, the base28hand the cover72may be threadably attached to the post74so as to rotate with respect to the post74. It will be understood that the base28hor the cover72may also be fixed to the post74in other embodiments. The post74may define a fastener opening34hfor receiving a fastener (not shown) for fastening the support member70to the ceiling14of the tunnel10, in a manner similar to the previously disclosed embodiments. Also, the base28hmay be positioned substantially parallel to the cover72, and the sockets36hmay be disposed at a non-perpendicular angle with respect to the base28h,as indicated at78. One embodiment of the present disclosure may include the sockets36hdisposed at an angle78of approximately 5 degrees, for example, such that the sockets36hmay extend at an angle of approximately 85 degrees with respect to the base28h.However, it will be understood that the sockets36hmay be disposed at other suitable angles within the scope of the present disclosure.

Another alternative embodiment of the present disclosure is shown inFIG. 19, which shows a plan view of a support member70a.The support member70amay be configured similar to the embodiment of the disclosure depicted inFIGS. 16-18, except that the support member70amay include five openings76aand five sockets36i.Moreover, the base28iand the cover72amay each have a substantial pentagonal shape.

It will also be understood that a support member70bmay be formed in various other shapes and configurations within the scope of the present disclosure, such as a substantially triangular shape base28jand cover72b,as shown in the plan view of the alternative embodiment of the disclosure depicted inFIG. 20. The support member70bmay thus include three openings76band three sockets36j.It will be understood, however, that the support member may be formed in various other shapes and the support member may have different numbers of openings and sockets within the scope of the present disclosure.

Reference will now to made toFIGS. 21 and 22to describe another alternative embodiment of the present disclosure. As previously discussed, the presently disclosed embodiments of the disclosure illustrated herein are merely exemplary of the possible embodiments of the disclosure, including that illustrated inFIGS. 21 and 22.

It will be appreciated that the alternative embodiment of the disclosure illustrated inFIGS. 21 and 22contains many of the same structures represented inFIGS. 1-20and only the new or different structures will be explained to most succinctly explain the features which come with the embodiments of the disclosure illustrated inFIGS. 21 and 22.

FIG. 21shows a plan view of another embodiment of a support member, indicated generally at80. The support member80may include a base28kthat may be somewhat square shaped. It will also be understood that the support member80may be formed in various different shapes within the scope of the present disclosure. The support member80may include sockets36kand a fastener opening34a.As shown inFIG. 22, which shows a side, cross-sectional view of the support member80taken along line A-A inFIG. 21, the base28kmay be substantially planar. Sockets36kmay be disposed on the base28kat an angle, such as approximately 5 degrees from perpendicular to the base28k,for example. Tapered washers82may be attached to the base28ksurrounding the sockets36kto provide support to the sockets36kon the base28k.Washers84may also be attached to the base28kon an opposite side of the base28kas the tapered washers82. It will be understood that the tapered washers82and the washers84may be welded to the sockets36kand the base28k,or the tapered washers82and the washers84may be joined to the base28kand/or sockets36kin any other suitable manner known to those skilled in the art. It will be understood that the tapered washer82and washer84may be utilized to support the sockets36kon the base28kin a stable manner even though the sockets36kmay be disposed at an angle with respect to the base28k.

It will also be understood that an additional embodiment of the support member80a,as shown inFIGS. 23 and 24, may be provided having three sockets361.FIG. 23depicts a plan view of the support member80a,whereasFIG. 24depicts a side, cross-sectional view of the support member80a,taken along line A-A ofFIG. 23. The support member80amay include a base281that forms a substantially triangular member.

Moreover, another alternative embodiment of the support member80b,as shown inFIGS. 25 and 26, may be provided having five sockets36m.FIG. 25depicts a plan view of the support member80b,whereasFIG. 26depicts a side, cross-sectional view of the support member80b,taken along line A-A ofFIG. 25. The support member80bmay include a base28mthat may form a substantially pentagonal member. However, as previously discussed, it will be understood that the support member may be formed in various different configurations.

Reference will now to made toFIGS. 27-29to describe an additional alternative embodiment of the present disclosure. As previously discussed, the presently disclosed embodiments of the disclosure illustrated herein are merely exemplary of the possible embodiments of the disclosure, including that illustrated inFIGS. 27-29.

It will be appreciated that the alternative embodiment of the disclosure illustrated inFIGS. 27-29contains many of the same structures represented inFIGS. 1-26and only the new or different structures will be explained to most succinctly explain the features which come with the embodiments of the disclosure illustrated inFIGS. 27-29.

FIG. 27shows an exploded perspective view of another alternative embodiment support member, indicated generally at86. The support member86may include a base88, one or more connectors90, a socket92, and a cover94. The base88may include an opening96that may be threaded for engaging with a connector90, that may also be threaded on an exterior surface. It will be understood that other attachment mechanisms may be used to attach the connector90to the base88within the scope of the present disclosure. The connector90may also threadably engage with the socket92for attaching the socket92to the base88. Accordingly, an interior of the socket92may also be threaded. Another connector90may be joined with the socket92and the cover94may be joined with the connector90, such as by threaded engagement, to enclose the socket92. It will be understood that some embodiments of the present disclosure may include components, such as the connectors90, sockets92and/or cover94, that may be obtained in the form of standard pipe equipment or fittings that may be commercially available, whereas in other embodiments, such components may be custom made as part of the support member86.

A plan view of the support member86is shown inFIG. 28, and a side cross-sectional view of the support member86, taken along line A-A inFIG. 28, is shown inFIG. 29. As shown most clearly inFIG. 29, the base88may have an inclined surface98circumscribing each of the openings96for receiving the socket92. The openings96may project substantially perpendicularly with respect to the inclined surface98such that the openings96may project at non-perpendicular angles with respect to a surface99of the support member86. Accordingly the openings96may project at angles converging toward each other to enable the roof bolts18to be installed through the openings96in a splayed configuration. It will be understood that the inclined surface98may extend at a 5 degree angle, or any other suitable angle, with respect to the surface99of the support member86.

As shown inFIG. 30, which shows a plan view of an alternative embodiment support member86a,the support member86amay have a base88ain different configurations for accommodating different numbers of sockets92aand inclined surfaces98a.For example, the support member86amay be configured to have three sockets92a.Moreover, as shown inFIG. 31, which shows a plan view of an additional alternative embodiment support member86b,the support member86bmay be configured to include any other quantity of sockets92b,such as five for example.

Referring toFIGS. 32 and 33, a support member80is depicted for illustrative purposes. The support member80is shown in plan view inFIG. 32, and in side view inFIG. 33. It will be understood that the support member80inFIGS. 32 and 33is merely representative of a variety of support members, and that the features discussed herein with respect toFIGS. 32 and 33may be applicable to various different embodiments of the support member. It will be understood that the support member80may be configured to receive roof bolts18in various different configurations. For example, the support member80may be configured to allow the roof bolts18to splay in a radial direction102, or a non-radial direction104with respect to the opening34k,or center of the support member80. Also, the support member80may be configured to allow the roof bolts18to extend in a parallel direction, or a combination of radial, non-radial, and/or parallel directions. Moreover, as shown inFIG. 33, the support member80may be configured to allow the roof bolts18to extend in a splayed direction106towards each other such that the roof bolts18may cross each other at a certain location. This configuration may sometimes be referred to as a reverse splay, or a splay in a reverse direction. It will also be understood that the roof bolts18may have the same or different lengths and sizes installed within a particular support member80. Accordingly, it will be understood that the roof bolts18may extend in a variety of different configurations within the scope of the present disclosure.

Referring now toFIG. 34, a side view is shown of an embodiment of a socket36nand cover46n.A roof bolt18having a bolt head24may be installed on a washer112within the socket36nin a manner as described above. One or more strain gauges108, or other signaling devices, may be disposed on the socket36nto provide a mechanism for monitoring the amount of load on or other characteristic of the bolt18or socket36n,or other component of the support member. It will be understood that the strain gauge108may be formed in any manner known to those skilled in the art for detecting loads. Moreover, the gauges108may be positioned as desired to obtain data at a specified location. The strain gauge108may include wires110extending to instrumentation or recording or display equipment. Alternatively, the strain gauge108may provide wireless output. It will be understood that the load on the strain gauge108may be read directly with an instrument or information from the gauge108may be transmitted to a storage device for remote readout. Some embodiments of the present disclosure may also allow transmitting and reading of data from the gauge108over wire or wire-less networks such as the Internet. It will be understood that other signaling devices known in the art may be used to monitor conditions at the support members within the scope of the present disclosure.

Referring now toFIG. 35, a perspective view of an alternative embodiment support member or anchor plate is shown, indicated generally at114. The anchor plate114may form a ring or base for anchoring any variety of structures, such as power poles, light poles, or windmills, for example. The anchor plate114may be set on rock or other material with bolts18drilled into the material through the anchor plate openings116. It will be understood that the shape and configuration of the anchor plate114, as well as the anchor plate openings116may vary within the scope of the present disclosure. Moreover, it will be understood that the anchor plate114may be placed against a ceiling, floor or wall, such that the anchor plate114may be oriented in any desired position with respect to surface or subsurface materials. Accordingly, the anchor plate114may provide a support for structures as an alternative to prior art supports in which a concrete base is poured over anchor bolts to embed the bolts in the concrete.

It will be appreciated that the structure and apparatus disclosed herein is merely one example of a means for directing bolts in a splayed configuration, and it should be appreciated that any structure, apparatus or system for directing bolts which performs functions the same as, or equivalent to, those disclosed herein are intended to fall within the scope of a means for directing bolts in a splayed configuration, including those structures, apparatuses or systems for directing bolts which are presently known, or which may become available in the future. Anything which functions the same as, or equivalently to, a means for directing bolts in a splayed configuration falls within the scope of this element.

In accordance with the features and combinations described above, a useful method for supporting a subsurface material includes the steps of:

attaching a support member to a surface of the material, the support member comprising a plurality of sockets, each of the sockets being configured for receiving a bolt therethrough;

installing a first bolt in the material through one of the sockets at a first pre-determined angle defined by the one of the sockets;

installing a second bolt in the material through another one of the sockets at a second pre-determined angle defined by the other one of the sockets.

Those having ordinary skill in the relevant art will appreciate the advantages provided by the features of the present disclosure. For example, it is a feature of the present disclosure to provide a support member that is simple in design and manufacture. Another feature of the present disclosure is to provide such a support member that is versatile in allowing different quantities of roof bolts to be used in connection with the support member, and allowing additional roof bolts to be installed at a later time in the event one or more of the roof bolts fail. It is a further feature of the present disclosure, in accordance with one aspect thereof, to provide a support member that provides increased support capabilities, in that more than one bolt may be installed in close proximity to create a higher load carrying capacity than a single bolt. It is another feature of the present disclosure to provide a support member that allows a plurality of roof bolts to be installed in a splayed manner in which the heads of the roof bolts may be in close proximity to each other, whereas the ends of the roof bolts may be spaced further apart, for supporting sub-surface materials that may not otherwise be supported. It is an additional feature of the present disclosure to provide a support member that may enhance safety and may prevent roof bolts from being ejected from the support member. It is another feature of the present disclosure to provide a support member that may provide a visual indicator as to a condition of the roof bolts. It is a further feature of the present disclosure to provide a support member that may be used to withstand the loading of high-strength cable roof bolts and bolts of various different varieties. It is another feature of the present disclosure to provide a support member that may be useful for stabilizing materials or slopes from above the ground.