US20120091783A1

US20120091783A1 - Expansion device for breaking solid material, use of the device and method for producing it

Info

Publication number: US20120091783A1
Application number: US13/378,500
Authority: US
Inventors: Anders Erik Daniel Ahnberg; Per Henrik Bojo
Original assignee: EMSTONE AB
Current assignee: EMSTONE AB
Priority date: 2009-06-17
Filing date: 2009-06-17
Publication date: 2012-04-19
Also published as: WO2010147522A1; CN102459812B; CN102459812A; EP2443316A1

Abstract

An expansion device for breaking solid materials, including at least one hose element having an inner expansion chamber with a non-circular cross section before pressurization or having an inner pressuring means and/or a reinforcement arranged on the outside of the inner expansion chamber which has a non-circular cross section before pressurization. The inner pressuring means is arranged around the inner expansion chamber and the reinforcement is arranged around the inner pressuring means. Optionally an outer layer is arranged around the reinforcement, having at least one “directional-breaking-force amending” material portion which is arranged outside the reinforcement. The at least one hose element has a coupling connection on a first end of the hose element, and optionally a second coupling connection on a second end of the hose element.

Description

TECHNICAL FIELD

The present invention relates to an expansion device for breaking solid material and to a method for production of the device.

TECHNICAL BACKGROUND

It has for a long time been a great challenge to find a way of cracking rock, stone, concrete and the like in a simple, cheap, quick and environmentally friendly way, while obtaining a predetermined directed expansive force.
Breaking of solid materials such as rock, stone, concrete and the like can be executed by drilling one or more holes in the material and then expanding the hole(s) to such an extent that the surrounding material cracks; e.g. by detonating explosives or by filling the drilled hole with a cement solution having the capacity to expand during curing, causing necessary bursting pressure for the surrounding material to crack. Other methods for expanding drilled holes and achieving the effect of breaking solid material include e.g. applying pressure with gas or high pressure water, tapping with wedges or using a variety of hose elements where pressure is applied with agents such as e.g. water, oil, and air, which cause expansion and force apart or break the solid material.
Reinforced hose, also called technical hose, hydraulic hose, or industrial hose, functions as a conventional hose i.e. transports or encapsulates e.g. fluid, but tolerates significantly higher pressure than a conventional hose. The reinforced hose endures high pressure due to the application of some kind of reinforcement material covering the inner hose; e.g. braided steel wire or aramid. The reinforcement can be applied to the inner hose in a number of ways; e.g. through braiding, weaving or knitting, and if required several layers of reinforcement can be applied with ply adhesion to further strengthen the construction.
Another way of manufacturing reinforced hose is by using reinforced cloth, which is rolled to obtain a cylindrical and concentric shape. Reinforced cloth is available in different designs and materials and is manufactured for a number of applications, e.g. hard-wearing bands, carpets, car tyres and different forms of reparations; but when rolled it can also be used as reinforced hose.
Hydraulic hose is commonly manufactured in a cylindrical shape for several reasons; e.g. the cylindrical shape is a durable construction, the flow area is significant in relation to material used, it has a concentric shape and is easy to manufacture. The hydraulic hose is normally supposed to be shape permanent or shape stable, and retain its original shape, but attempts to manufacture expanding hydraulic hoses for breaking rock have been made by e.g. Dunlop, British patency application no. GB1180915, already in 1965. In this application, Dunlop use special angles between the reinforced wires, resulting in a minor radial expansion of the hose, but at the cost of the hose contracting along its longitudinal axis. A problem arising when changing the normal braiding angle of e.g. about 54 degrees, which Dunlop advocates in order to break solid materials, is that the hose's increasing radial expansion inevitably results in a longitudinal contraction. The radial expansion achieved through changing the reinforcement angle alone is not sufficient to acquire effective breaking effect. Furthermore, the expansion device risks being pulled apart when contracting longitudinally while simultaneously pressing against the inner surface of the drilled hole.
Other examples of reinforced hose, though intended for significantly lower pressures than the hydraulic hose from Dunlop described above, which are not always circularly shaped, are fire hoses, which, in order to occupy less space during transport and unfolding, are flattened when not filled with water.
Moreover, PCT/SE2007/000138 discloses a device for breaking solid material comprising an expansible hose element which is insertable into a hole in the solid material and has an externally substantially geometrically regular cross-section. At least at one of its ends, the hose element comprises a coupling. The device further comprises at least one expansion portion with an expansion chamber. The hose element further comprises an expansion limiter which has a varying radial distance from the outside of the hose element along the circumferential direction of the hose element.
Furthermore, PCT/SE2008/000377 discloses a procedure for the manufacturing of an expansion device for breaking of solid material, wherein the procedure is made by use of a mandrel. The expansion device constitutes a reinforced hose construction which before pressurisation has a non-cylindrical reinforcement, which at pressurisation gradually obtains a more cylindrical shape and whose expansion comes to an end only at full cylindrical shape. The procedure according to one embodiment of PCT/SE2008/000377 is made by the following steps, wherein a tight inner hose of the hose construction is applied to a mandrel first, thereafter at least one layer of reinforcement is applied to the tight inner hose, the mandrel with inner hose and reinforcement are compressed, the compressed inner hose with external compressed reinforcement is coated with a material creating at least one outer pressure element with a substantially outer cylindrical shape; and finally the compressed mandrel is removed.
There are some problems related to the devices according to PCT/SE2007/000138 and PCT/SE2008/000377. In relation to the production of the devices according to these patent applications, PCT/SE2007/000138 discloses a possible method for manufacturing flattened reinforced hose construction, but this method does not take into account whether the flattening process should be done with or without mandrel. Reinforced hose is commonly manufactured on a homogenous plastic or rubber mandrel, which results in that the hose cannot be completely flattened so long as the mandrel is still inside the hose. The production method according to PCT/SE2008/000377 solves this problem by the use of a mandrel, however, this implies some other negative effects, such as a difficult and time consuming production. Moreover, the production method according to PCT/SE2007/000138 and most of the method embodiments according to PCT/SE2008/000377 are foremost designed for use of rubber materials, which implies that the methods involve vulcanization which is quite time consuming and expensive. Furthermore, although the devices disclosed in PCT/SE2007/000138 and PCT/SE2008/000377 are designed for use at really high pressures, there are limits for the pressure possible to apply, such as about 1000 bar.
Therefore, one object of the present invention is to provide an expansion device for breaking solid material, such as stone, rock, concrete and the like, which is optimal for use at high pressures.

SUMMARY OF THE INVENTION

The object above is solved by an expansion device for breaking solid materials, wherein the expansion device comprises at least two hose elements, each hose element comprising:

- an inner expansion chamber having a non-circular cross section before pressurization or having an inner pressuring means and/or a reinforcement arranged on the outside of the inner expansion chamber which have a non-circular cross section before pressurization;
- the inner pressuring means which is arranged around the inner expansion chamber;
- the reinforcement which is arranged around the inner pressuring means;
- optionally an outer layer arranged around the reinforcement;
- optionally at least one “directional-breaking-force amending” material portion which is arranged outside the reinforcement or outside the optional outer layer;
- and wherein
- each hose element comprises a coupling connection on a first end of the hose element, and optionally a second coupling connection on a second end of the hose element;
and wherein
the expansion device comprises an outer pressuring means which is arranged on the outside of and encapsulates said at least two hose elements, at least a portion between the coupling connection on the first end of each hose element and the optional second coupling connection on the second end of each hose element.

It is important to realize that the expression “at least a portion between the coupling connection on the first end of each hose element and the optional second coupling connection on the second end of each hose element” embodies an outer pressuring means being provided from the coupling connection on the first end of each hose element and down to the optional second coupling connection on the second end of each hose element, but is also valid for an embodiment where the outer pressuring means is provided a portion between these coupling connections. This interpretation of the expression is valid throughout the entire description.
The expansion device according to the present invention is preferably intended for use of hydraulic pressurized mediums, such as hydraulic oil, but pressurized water or compressed air could also be used. The medium is pumped or flowed into the inner expansion chamber(s) when the expansion device is inserted into a hole of the solid material being intended to break or crack, and when pressure is built up inside the expansion chamber(s), the outer pressuring means of the expansion device presses against the solid material which eventually breaks or cracks.
As may be noted from above, the expansion chamber according to the above specified specific embodiment of the present invention comprises at least two hose elements. Due to the plurality of the hose elements, it is possible to apply a very high pressure, which in turn gives an effective cracking of solid materials. However, this effective cracking could also be accomplished in another way according to the present invention, and that is by use of pulsation for the pressure built up of the pressurized medium. As an example, by use of pulses or impulses, the pressure may be raised from 200 to 1000 bar in a matter of milliseconds. Therefore, according to another specific embodiment of the present invention, there is provided an expansion device for breaking solid materials, wherein the expansion device comprises at least one hose element comprising:

- an inner expansion chamber having a non-circular cross section before pressurization or having an inner pressuring means and/or a reinforcement arranged on the outside of the inner expansion chamber which have a non-circular cross section before pressurization;
- the inner pressuring means which is arranged around the inner expansion chamber;
- the reinforcement which is arranged around the inner pressuring means;
- optionally an outer layer arranged around the reinforcement;
- optionally at least one “directional-breaking-force amending” material portion which is arranged outside the reinforcement or outside the optional outer layer;
- and wherein
- said at least one hose element comprises a coupling connection on a first end of the hose element, and optionally a second coupling connection on a second end of the hose element;
wherein
the expansion device comprises an outer pressuring means which is arranged on the outside of and encapsulates said at least one hose element, at least a portion between the coupling connection on the first end of the hose element and the optional second coupling connection on the second end of the hose element,
and wherein
the coupling connection on the first end of the hose element, and optionally the second coupling connection on the second end of the hose element, is arranged to be connected to a device provided to generate at least one pulse of pressurized medium inflow.

According to the present invention, the pressure may be raised from about e.g. 200 to 1000 bar in a matter of milliseconds. Therefore, according to the specific embodiment disclosed above, there may be provided only one hose element inside of the expansion device. However, according to this specific embodiment, it is of course also possible that the expansion device comprises at least two hose elements.
Just to increase the understanding, it should be noted that the term “solid material” refers to a material which is in solid state at normal outdoor temperatures, such as rock and concrete. In addition to the traditional range of uses, the present invention also finds use in or under water, where other traditional methods are not possible or suitable to use.
In the explanation below, the term “hose element” may refer to several hose elements, as may be understood by the specific embodiment of the present invention disclosed above. The same goes for the expression “expansion chamber”.
The cross-section of the expansion chamber is such that the relationship between the longest distance between the walls and the shortest distance decreases as the hose element changes from an unpressurised to a pressurised state. In the unpressurised state, the expansion chamber thus has a non-circular cross-section, the expansion chamber being arranged to aim at a circular cross-section when pressurised. The pressurisation makes the hose element expand in a direction parallel with the line that represents the shortest distance between two opposite walls in the expansion chamber in the unpressurised state.
In relation to the actual cross sections of different portions of the expansion device according to the present invention, these may vary. As will be explained in more detail below, the inner pressuring means, the reinforcement and/or the optional outer layer may e.g. have a petal-like, elliptical, convex or banana-like shape before pressurization. Furthermore, the outer pressuring means may e.g. have a circular cross section, but may also have e.g. a diamond shaped, triangular or a cubical shaped cross section in the longitudinal direction of the expansion device.
As mentioned above, the hose element of the expansion device comprises an inner pressuring means which is arranged around the inner expansion chamber, i.e. creates the expansion chamber. The inner pressuring means may have a flattened semi-cylindrical cross section, but may also have other shapes.
Moreover, the reinforcement arranged around the inner pressuring means may be arranged in different shapes, such as tightly around the inner pressuring means but may also have other shapes. This is explained in more detail below.
Furthermore, there may also optionally be provided an outer layer arranged around the reinforcement. This layer is not a must, but may function as e.g. a protecting or reinforcing layer. The optional outer layer arranged around the reinforcement may for instance be of a plastic material or a rubber material.
The hose element optionally also includes at least one “directional-breaking-force amending” material portion which is arranged outside the reinforcement. This additional material portion may be arranged to alter the stiffness or flexibility of the entire device in one or more directions, thus changing the directional breaking force. The additional “directional-breaking-force amending” material portion may be arranged around the reinforcement or optional outer layer arranged around the reinforcement, but may also constitute single or multiple parts arranged against the reinforcement at one or more specific places. Moreover, this or these material portions may also be positioned inside of the outer pressuring means. Nevertheless, the at least one “directional-breaking-force amending” material portion is provided to amend the directional breaking force in one or more directions by amending the stiffness or flexibility at specific places of the expansion device. The optional outer layer arranged around the reinforcement may also have stiffening or flexing properties, and thus emending the breaking force. Moreover, according to one specific embodiment of the present invention, there is provided an expansion device for breaking solid materials, wherein the expansion device comprises at least one hose element comprising:

- an inner expansion chamber having a non-circular cross section before pressurization or having an inner pressuring means and/or a reinforcement arranged on the outside of the inner expansion chamber which have a non-circular cross section before pressurization;
- the inner pressuring means which is arranged around the inner expansion chamber;
- the reinforcement which is arranged around the inner pressuring means;
- optionally an outer layer arranged around the reinforcement;
- optionally at least one “directional-breaking-force amending” material portion which is arranged outside the reinforcement or outside the optional outer layer;
- and wherein
- said at least one hose element comprises a coupling connection on a first end of the hose element, and optionally a second coupling connection on a second end of the hose element;
wherein
two “directional-breaking-force amending” means are positioned on opposite sides of said at least one hose element, outside the reinforcement or the optional outer layer arranged around the reinforcement, which two “directional-breaking-force amending” means are held against the hose element by at least one tightening means around the two “directional-breaking-force amending” means;
and wherein
the expansion device optionally also comprises an outer pressuring means which is arranged on the outside of and encapsulates said at least one hose element and the two “directional-breaking-force amending” means, at least a portion between the coupling connection on the first end of the hose element and the optional second coupling connection on the second end of the hose element.

According to this specific embodiment of the present invention, the at least one “directional-breaking-force amending” material portion is in fact provided as two “directional-breaking-force amending” means on opposite sides of said at least one hose element, outside the reinforcement or in this case maybe also outside the optional outer layer arranged around the reinforcement. The material of the “directional-breaking-force amending” means may vary, but one example is metallic materials, but other stiff and hard materials are also possible.
The “directional-breaking-force amending” means may comprise some grooves so that the capability to tighten the “directional-breaking-force amending” means against the reinforcement is increased by use of e.g. threads, such as flexible threads. The flexibility of the threads may also ensure that the expansion device returns to its initial shape after de-pressurization. The use of elastic thread is however optional. For example soft polyurethane is also possible to use when incorporating the “directional-breaking-force amending” means against the reinforcement.
Moreover, according to one specific embodiment, each “directional-breaking-force amending” means has a cross section being half cylindrical, triangular, quadratic or a combination thereof, and extends at least a portion along and outside the length of the hose element. As an example, each “directional-breaking-force amending” means may be made of steel but also other materials, e.g. as a half cylindrically shaped steel means, e.g. extending along substantially the whole length of the hose element, from closely to the coupling connection on the first end of the hose element and to the second end of the hose element and the optional second coupling connection thereof.
Finally, in relation to the hose element, this also comprises a coupling connection on a first end of the hose element, and optionally a second coupling connection on a second end of the hose element. The coupling connection on the first end is arranged for connection to a suitable device, such as a coupling, to allow incoming medium or fluid to enter the expansion chamber of the hose element. In general, when manufacturing the ends of the hose element, e.g. after flattening a part of the hose element, the ends should not be made longer than required so that conventional hydraulic couplings can be applied to the hose element. The ends being connected to conventional hydraulic couplings are in general round, but other shapes are possible.
There may also be a second coupling connection provided on the second end of the hose element also, but this is in that case normally connected to an end coupling or a blind plug, so that the hose element is securely sealed from leakage at the second end. The second coupling connection may, however, also be connected, via some kind of adapter, to another coupling connection of another hose element so that expansion devices according to the present invention may be interconnected to each other.
As mentioned, the expansion device according to the present invention also comprises an outer pressuring means which is arranged on the outside of said at least one or two hose elements. Holes drilled in rock, for instance, mostly have a circular cross-section, and the expansion device preferably has a complementary shape. However, as said, the outer pressuring means may have different cross section shapes, such as diamond shaped, triangular or cubical shaped. The expansion device may also be somewhat flexible, such as in those cases where the holes in the material that is to be broken are not straight.
Moreover, as mentioned, the at least one hose element is contained inside of the outer pressuring means, at least up to the coupling connection on the first end of the hose element. This implies that the coupling connection on the first end may extend in the longitudinal direction of the expansion device without or only somewhat being surrounded by the outer pressuring means. This is also valid for the second end if a second coupling connection is provided on that end.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 shows the cross section of a hose element before it has been flattened according to the present invention.

FIG. 2 shows a flattened hose element of an expansion device according to the present invention.

FIG. 3 shows the cross section of one embodiment of an expansion device according to the present invention.

FIG. 4 a shows the cross section of one embodiment of an expansion device according to the present invention and FIG. 4 b shows that embodiment of an expansion device according to the present invention in section and aslant from the side where the outer pressuring means is not shown. FIG. 4 c shows the same embodiment but in this case the outer pressuring means is also shown.

FIGS. 5 a, 6 a and 7 a, respectively, show cross sections of different embodiments according to the present invention, and FIGS. 5 b, 6 b and 7 b, respectively, show those embodiments aslant from the side.

FIG. 8 shows a device provided to generate at least one pulse of pressurized medium inflow to several expansion devices according to one specific embodiment of the present invention.

FIG. 9 a shows the cross section of an expansion device according to one specific embodiment of the present invention, and FIG. 9 b shows that embodiment aslant from the side.

FIGS. 10 a and 11 a, respectively, show cross sections of different embodiments according to the present invention, and FIGS. 10 b, and 11 b, respectively, show those embodiments aslant from the side.

FIG. 12 shows a hose element according to the present invention having a coupling on one end and a blind plug on the other end.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will be described in more detail below. According to one specific embodiment of the present invention, said at least one or two hose elements comprise a coupling connection connected to a coupling on the first end of said at least one or two hose elements and comprise a blind plug on the second end of said at least one or two hose elements, the blind plug optionally being connected to a second coupling connection. As mentioned above, the blind plug may in fact be an end coupling which in that case is connected to a second coupling connection on the second end of the hose element. However, the blind plug may e.g. also be casted as a blind plug directly from the outer pressuring means material. According to this embodiment, the blind plug could be said to be an actual part of the outer pressuring means material, that is the blind plug on the second end of the hose element is provided as a casted blind plug. The intended effect is nevertheless to seal the second end of the hose element so that leakage is prevented at this end when hydraulic medium or fluid is pumped into and pressurized inside of the hose element.
As mentioned above, the expansion device according to one specific embodiment comprises at least two hose elements which at least up to each coupling connection on each first end of each hose element are encapsulated by the outer pressuring means. By use of more hose elements than one inside of the expansion device according to the present invention, it may be possible to achieve several advantages for some applications. Firstly, it is possible to apply a higher pressure in comparison to if only one hose element is encapsulated by the outer pressuring means. Secondly, by use of several hose elements, it is possible to increase an intended directional breaking force from the expansion device. By use of at least two hose elements, at least one first hose element is provided to initiate a crack in the solid material and at least one second hose element is provided to expand and press apart the solid material. In this case, the first hose element may be called a high pressure hose and the second hose element a low pressure hose with high expansion capabilities. This directional breaking effect may according to the present invention also be accomplished by use of materials with different hardness/stiffness inside of the expansion device at different places, such as between the outer pressuring means and the optional outer layer around the reinforcement. Several hose elements as well as e.g. hard parts of metal or plastic at the right places to increase both the intended directional breaking force and the possible hydraulic pressure to apply is also possible according to the present invention. The magnitudes of effects disclosed above and provided by the present invention are not possible to achieve by other similar expansion devices, such as the ones disclosed in PCT/SE2007/000138 and PCT/SE2008/000377.
It is important to understand that, according to the present invention, it is quite possible to provide more than two hose elements inside of the expansion device. By use of several hose element, the dimension of the expansion device increases in comparison. The size or “diameter” of the expansion device according to the present invention may vary, of course in relation to the sizes of the drill holes intended to be filled with the device. However, the expansion device according to the present invention also finds use for large drill holes, such as between e.g. 50 and 300 mm in diameter.
The different parts of the expansion device may be of different materials. According to one specific embodiment of the present invention, the inner pressuring means and/or the optional outer layer arranged around the reinforcement is made of a polymeric material, such as polyester, polyurethane, rubber, or a combination thereof.
The reinforcement of the expansion device may be of different type. The reinforcement material consists of fibers which are built up by steel and/or polymers, such as aramids. One example is a Kevlar® material. Outside the reinforcement there may be provided at least one “directional-breaking-force amending” material portion, that is an optional outer layer or part of different material, e.g. inside of the outer pressuring means. However, the outer pressuring means material may also be directly applied to the reinforcement. According to one specific embodiment of the present invention, the at least one “directional-breaking-force amending” material portion and/or the outer pressuring means is made of a material comprising polymeric materials such as polyurethane or rubber, steel, or a composite material, or a combination thereof. Examples are elastomeric materials and metallic materials. These materials are also possible for specific parts or portions positioned outside of the reinforcement but inside the outer pressuring means, which specific parts or portions may be provided to increase the directional breaking effect discussed above. As may be noted from above, the different parts of the expansion device according to the present invention may be of different materials, which is decided in relation to the intended use.
Additionally, the outer pressuring means material may also comprise other components. According to one specific embodiment of the present invention, the material of the outer pressuring means also comprises fibers extending in the longitudinal direction of the expansion device. These fibers may be provided to decrease the risk for the material of the outer pressuring means to extrude or float out over the coupling due to the high pressure. The fibers may keep the material together axially (along the longitudinal axis) without preventing radial extension. These fibers may e.g. yield very little elongation or have some flexibility. Polymer fibers, such as Kevlar, or glass fibers are possible examples to use. With polymer fibers or the like, the material of the outer pressuring means is allowed to reshape to some extent.
Another possible way to incorporate fibers in the outer pressuring means material according to the present invention is by use of short fibers, such as up to about 3 mm in length. These may be provided to change the crack tendency of the material.
As mentioned above, parts of other materials having some specific properties may be positioned inside of the expansion device outside of the reinforcement and optional outer layer arranged around the reinforcement. This or these “directional-breaking-force amending” material portions arranged outside the reinforcement may be provided directly against the reinforcement or optional outer layer arranged around the reinforcement, or may be casted, or vulcanized if the used outer material is a rubber material, into the outer pressuring means. These amending material portions may have very different designs and be of different materials. As an example, triangles, cubes or half cylinders may be mentioned. As a very specific example, half cylinders of a metallic material, e.g. of steel, may be positioned directly outside the reinforcement. These half cylinders may e.g. be positioned closely to the second end of the expansion device. Moreover, they may e.g. have grooves ensuring the possibility of easily securing the half cylinders against the reinforcement with thread, e.g. on two opposite sides of the reinforcement. Moreover, the thread used may be elastic so that the expansion device “goes back” to its initial shape after the de-pressurization. As may be understood, this is only one example of two “directional-breaking-force amending” material portions, positioned opposite to one another, and they could be positioned at other places and with different materials and designs. The common property is of course the amendment of the “directional breaking force” provided by such material portions, at pressurization of the expansion device.
Moreover, according to the present invention it is also possible to ensure the breaking force in other ways. There may for instance be provided an indication of fracture in the material intended to crack before use of an expansion device according to the present invention. This is also to make sure that the breaking force will be generated increasingly from that indication and/or to provide the possibility of controlling the crack through the solid material intended to crack.
The coupling connections and couplings may have different designs according to the present invention. According to one specific embodiment of the present invention, each end coupling and/or blind plug of each second end of said at least one or two hose elements is flat in design. End couplings having flat designs do not need that much space as round end couplings (see figures and detailed description of the figures below for a better understanding). As mentioned above, a casted blind plug is also possible. The possible advantage of providing flat coupling connections, couplings and/or end couplings is the fact that it may be possible to encase more hose elements with coupling connections inside of the expansion device. The coupling connections and couplings normally take up much space, and hence it may be of advantage to make these as flat as possible. By use of flat couplings, the possible variation of volume inside of the expansion device and as such the length of stroke/expansion may be increased. In other words, it is possible to increase the amount of hydraulic fluid pumped or flowed into the expansion device.
In relation to the designs of other different parts of the expansion device, these designs may also vary. According to one specific embodiment of the present invention, anyone, two or all of the inner pressuring means, the reinforcement and the optional outer layer have a petal-like (“four-leaved clover” shaped), elliptical, convex or banana-like shape, which are examples of non-circular shapes. An oval shape is another such example. The hose element may of course have a longitudinal circular cross section, and as mentioned before, a flattened external design of the hose element is also possible, the latter giving a ‘straight’ elliptic cross-section. This may be accomplished by compressing the hose element e.g. equally from two opposite sides. Moreover, if the hose element is compressed equally from e.g. four or six sides, a compressed hose element with a petal-shaped cross-section is obtained. As explained in PCT/SE2008/000377, if a compressed hose element with a straight, elliptic cross-section e.g. is exposed to pressure from only one direction, the cross-section is changed to a bent, banana-like, shape. Hereby, a greater length of the compressed hose element and its outer reinforcement can fit within a given outer diameter of the external outer pressuring means. Thereby, a greater expansion of the device is created with pressurisation, the result being a greater bursting force. With e.g. a banana-like shape it is possible to decrease the “diameter” of the inner pressing means in comparison to a flattened inner pressing means, and as such decrease the diameter of the drill hole used.
As mentioned in PCT/SE2008/000377, it is also according to the present invention possible to apply the reinforcement and thereafter optionally the optional outer layer in a petal-like, elliptical, convex or banana-like shape. The difference in relation to these different shapes or designs between the present invention and PCT/SE2008/000377 is the fact that a mandrel is used for the production of the devices according to PCT/SE2008/000377.
As is noted above, it is possible to use different mediums for the expansion device according to the present invention. As pulses may be preferable to use in some cases, air may be of interest to use but liquids are of course also possible to use. Therefore, according to one specific embodiment of the present invention, the device provided to generate at least one pulse of pressurized medium inflow is a cartridge containing at least one explosive component, such as gunpowder or dynamite.
According to the present invention it is also possible to provide a breaking force in other ways than by pressure built up of a hydraulic medium.
The breaking force may be accomplished by a phase transition (solid/liquid/gas) of a medium contained inside of the expansion device, the phase transition giving a volume increase. The phase transition may be provided by changing the temperature or pressure. The cracking force may according to the present invention also be provided by a chemical reaction, such as in the case of expandable cement.
Therefore, according to one specific embodiment of the present invention there is provided an expansion device for breaking solid materials, wherein the expansion device comprises at least one hose element comprising:

- an inner expansion chamber having a non-circular cross section before pressurization or having an inner pressuring means and/or a reinforcement arranged on the outside of the inner expansion chamber which have a non-circular cross section before pressurization;
- the inner pressuring means which is arranged around the inner expansion chamber;
- the reinforcement which is arranged around the inner pressuring means;
- optionally an outer layer arranged around the reinforcement;
- optionally at least one “directional-breaking-force amending” material portion which is arranged outside the reinforcement or outside the optional outer layer;
- and wherein
- said at least one hose element optionally comprises a coupling connection on a first end of the hose element, and is blinded on a second end of the hose element;
wherein
the expansion device comprises an outer pressuring means which is arranged on the outside of and encapsulates said at least one hose element, at least a portion between the coupling connection on the first end of the hose element and the optional second coupling connection on the second end of the hose element,
and wherein
the expansion device is provided to expand inside of the expansion chamber by means of at least one “indirectly expanding” component or mixture by means of a phase transformation of the component or mixture via change in temperature or pressure and/or by means of a chemical reaction.

The expression “indirectly expanding” component or mixture refers to a component or mixture which expands in volume due to a phase transition thereof via change in temperature or pressure. This may also be accomplished by a chemical reaction.
According to this specific embodiment, the second end of the hose element is blinded, e.g. by a blind plug, such as a casted blind plug. The first end, however, may also be blinded, but may also comprise a coupling which may be connected to a suitable device for filling the expansion chamber with at least one component which renders expansion without an external pressure built up. When the hose element is blinded at both ends, the expansion device is fully sealed before use. According to this specific embodiment, the expansion chamber contains e.g. at least two different components which are separated from each other, such as by a membrane. At use of the expansion device, the membrane is cracked, e.g. by heat, and the components are mixed with each other and reacted.
Moreover, according to the present invention there is also provided the use of an expansion device for the breaking or cracking of solid materials by use of a pressurised hydraulic medium. According to one specific embodiment, increase of pressure is made gradually and by pulsation. This may be of advantage due to the fact that the energy created by pulsation is higher in comparison to an evenly held pumping pressure, and hence the formation of cracks is better and increased.
According to another specific embodiment, there is provided the use of an expansion device according to the present invention, for the breaking or cracking of solid materials by use of at least one “indirectly expanding” component or mixture which expands by means of a phase transformation of the component or mixture via change in temperature or pressure and/or by means of a chemical reaction.
One object of the present invention is also to provide an effective method for production of an expansion device according to the present invention.
Therefore, according to the present invention, there is provided a method for the production of an expansion device according to the present invention, the method comprising the following steps:

producing at least one hose element by
- applying the reinforcement around the inner pressuring means;
- optionally applying the outer layer around the reinforcement;
- optionally providing the coupling connection on the first end of the hose element, optionally also providing the second coupling connection on the second end of the hose element;
- optionally connecting a coupling or a blind plug to any coupling connection;
optionally providing the at least one “directional-breaking-force amending” material portion which is arranged outside the reinforcement or outside the optional outer layer; and
casting or vulcanization of the expansion device, wherein the outer pressuring means is arranged and casted or vulcanized on the outside of said at least one hose element, said outer pressuring means encapsulating said at least one hose element, at least up to the optional coupling connection on the first end of said at least one hose element, and also encapsulating the optional at least one “directional-breaking-force amending” material portion, said outer pressuring means optionally also sealing the first end and/or the second end, each by a casted blind plug.

According to one specific embodiment, at least two hose elements are produced and the outer pressuring means is casted or vulcanized to encapsulate the at least two hose elements in one expansion device.
According to yet another specific embodiment, at least one part of said at least one hose element is flattened during the application of an increased temperature, e.g. of between 90 and 200° C. This is possible to achieve by different methods, such as without the need for an overpressure.
As is disclosed above, according to one embodiment of the present invention a blind plug is provided on the second end of said at least one hose element, by casting or optionally by connection to a provided second coupling connection. The latter is made by the connecting of an end coupling to the second coupling connection.

DETAILED DESCRIPTION OF THE FIGURES

FIG. 1 shows a hose element 2 having an inner expansion chamber 3, an inner pressuring means 4 which is arranged around the inner expansion chamber 3 and a reinforcement 5 which is arranged around the inner pressuring means. The hose element 2 also has an outer layer 6 arranged around the reinforcement, which outer layer 6 is optional according to the present invention. The hose element 2 shown in FIG. 1 has an inner expansion chamber 3 with a circular cross section. This is due to the fact that the hose element 2 shown in FIG. 1 has not yet been flattened according to the present invention giving a non-circular cross section.
FIG. 2 shows a flattened hose element 2 of an expansion device 1 according to the present invention. The flattened hose element 2 has a non-circular inner expansion chamber 3 inside of the hose element 2. The hose element 2 has a first end 9 having a coupling connection 8 which is connected to a coupling 16, and a second end 11, which in this case has a second coupling connection 10 which is connected to a blind plug 17. This specific embodiment is a single or end expansion device 1, which implies that a pressure medium or fluid is to be applied from a device with e.g. a regular hose which is connected to the coupling 16 on the first end 9 of the hose element 2. On the other end, the second end 11, however, there is provided a blind plug 17, which in this case is connected to a coupling connection 10, giving a stop end of the hose element 2 and expansion device 1. It is important to realize that, according to the present invention, it is also fully possible to provide a casted blind plug 17 on e.g. the second end 11, e.g. without the need for a coupling connection 10 on that end 11. Moreover, coupling connections (8, 10) and couplings 16 may also be provided on both ends (9, 11) of the hose element 2 so that such an expansion device 1 may be a middle expansion device 1 which is connected to other expansion devices 1, in an expansion device system according to the present invention. Finally, there may also be provided blind plugs 17 on both ends (9, 11) of the hose element, but in this case the expansion device 1 will comprise some kind of “indirectly expanding” component or mixture which will expand inside of the expansion chamber 3 by means of a phase transformation of the component or mixture via change in temperature or pressure and/or by means of a chemical reaction.
FIG. 3 shows the cross section of one embodiment of an expansion device 1 according to the present invention. According to this specific embodiment of the present invention, there is provided two hose elements 2 inside of the expansion device 1, each hose element 2 having a non-circular expansion chamber 3, an inner pressuring means 4 which is arranged around the inner expansion chamber 3 and a reinforcement 5 which is arranged around the inner pressuring means. Outside of the hose elements 2 there is provided an outer pressuring means 12 which is arranged on the outside of and encapsulates said two hose elements 2. It is important to understand that the expansion device 1 according to the present invention may comprise more hose elements 2 than two (see e.g. FIGS. 4 a, 4 b and 4 c).
FIG. 4 a shows the cross section of one embodiment of an expansion device 1 according to the present invention, having three hose elements 2 and an outer pressuring means 12 which is arranged on the outside of and which encapsulates the three hose elements 2.
FIG. 4 b shows the specific embodiment of the expansion device 1 according to FIG. 4 a aslant from the side, where the outer pressuring means 12 is not shown. In this figure it is easy to see that each hose element 2 has been provided with a blind plug 17, which in this case is a casted blind plug 17 for the entire expansion device 1. Such a blind plug 17 may e.g. be casted in the same material as the material of the outer pressuring means 12.
FIG. 4 c shows the same embodiment as FIGS. 4 a and 4 b, but with reference to FIG. 4 b, FIG. 4 c. also shows the outer pressuring means 12.
FIG. 5 a shows the cross section of one specific embodiment of an expansion device 1 according to the present invention. Inside of the expansion device 1 there is provided, in this case, one hose element 2. Outside of the hose element 2 there are positioned two “directional-breaking-force amending” means 13 on opposite sides of the hose element 2, which two “directional-breaking-force amending” means 13 each is in the shape of a half cylinder or part of a cylinder. The two “directional-breaking-force amending” means 13 are held against the hose element 2 by at least one tightening means 14 around the two “directional-breaking-force amending” means 13, which tightening means 14 in this case also constitutes the outermost layer of the expansion device 1. It is important to understand that a “directional-breaking-force amending” means 13 may also be seen as an optional “directional-breaking-force amending” material portion 7 according to the present invention. However, such a “directional-breaking-force amending” material portion 7 may also e.g. be provided as a single portion or part on only one side outside of the hose element 2 according to the present invention.
FIG. 5 b shows the specific embodiment according to FIG. 5 a a slant from the side.
FIGS. 6 a and 6 b show a similar specific embodiment to the one disclosed in FIG. 5 a and FIG. 5 b, but in this case each “directional-breaking-force amending” means 13 has rectangular shape.
FIGS. 7 a and 7 b show a similar specific embodiment to the one disclosed in FIG. 5 a and FIG. 5 b, but in this case each “directional-breaking-force amending” means 13 has a triangular cross sectional shape. Moreover, according to the specific embodiment disclosed in FIGS. 7 a and 7 b, there is also provided an outer layer 6 arranged around the reinforcement 5 of the hose element 2.
FIG. 8 shows a device 15 provided to generate at least one pulse of pressurized medium inflow to several expansion devices 1 according to one specific embodiment of the present invention. Such a system may be referred to as an expansion device system according to the present invention.
FIG. 9 a shows the cross section of an expansion device 1 according to one specific embodiment of the present invention, and FIG. 9 b shows that embodiment aslant from the side. According to this specific embodiment, the outer pressuring means 12 comprises fibers extending in the longitudinal direction of the expansion device 1.
FIG. 10 a shows the cross section of one specific embodiment of an expansion device 1 according to the present invention. FIG. 10 b shows that specific embodiment aslant from the side. According to this specific embodiment, the hose element 2 has a banana-like shape before pressurization. Also in this case, an outer pressuring means 12 is provided outside of the hose element 2. Moreover, also in this case it is according to the present invention possible to incorporate several hose elements 2 inside of the expansion device 1.
FIGS. 11 a and 11 b show another specific embodiment of an expansion device 1 according to the present invention, in line with the embodiment shown in FIGS. 10 a and 10 b. However, in this case the hose element 2 has a petal-like shape before pressurization.
It is important to understand that FIG. 11 show a hose element 2 which in fact has an expansion chambers 3 which are circular before and after de-pressurization, but which specific embodiment still is a part of the present invention. However, in this case the inner expansion chamber 3 has an inner pressuring means 4 and a reinforcement 5 which are arranged on the outside of the inner expansion chamber 3 and which have a non-circular cross section before pressurization.
FIG. 12 shows a hose element 2 according to the present invention, but in this case there is provided a blind plug 17 on the second end 11, which is of another type in comparison with FIG. 2. Moreover, a coupling connection 8 and coupling 16 are provided on the first end 9 of the hose element 2. It is important to realize that both a blind plug 17 and a coupling 16 may be flat in shape so that they do not need much space. This may e.g. be of interest when several hose elements 2 are provided inside of an expansion device 1 according to the present invention.

Claims

1. Expansion device (1) for breaking solid materials, wherein the expansion device comprises at least two hose elements (2), each hose element (2) comprising:

an inner expansion chamber (3) having a non-circular cross section before pressurization or having an inner pressuring means (4) and/or a reinforcement (5) arranged on the outside of the inner expansion chamber (3) which have a non-circular cross section before pressurization;

the inner pressuring means (4) which is arranged around the inner expansion chamber (3);

the reinforcement (5) which is arranged around the inner pressuring means;

optionally an outer layer (6) arranged around the reinforcement;

optionally at least one “directional-breaking-force amending” material portion (7) which is arranged outside the reinforcement (5) or outside the optional outer layer (6);

and wherein

each hose element (2) comprises a coupling connection (8) on a first end (9) of the hose element (2), and optionally a second coupling connection (10) on a second end (11) of the hose element (2);

and wherein

the expansion device (1) comprises an outer pressuring means (12) which is arranged on the outside of and encapsulates said at least two hose elements (2), at least a portion between the coupling connection (8) on the first end (9) of each hose element (2) and the optional second coupling connection (10) on the second end (11) of each hose element (2).

2. Expansion device (1) according to claim 1, wherein at least one hose element is a high pressure hose, and wherein at least one hose element is a low pressure hose.

3. Expansion device (1) for breaking solid materials, wherein the expansion device (1) comprises at least one hose element (2) comprising:

the inner pressuring means (4) which is arranged around the inner expansion chamber;

the reinforcement (5) which is arranged around the inner pressuring means;

optionally an outer layer (6) arranged around the reinforcement;

and wherein

said at least one hose element (2) comprises a coupling connection (8) on a first end (9) of the hose element (2), and optionally a second coupling connection (10) on a second end (11) of the hose element (2);

wherein

two “directional-breaking-force amending” means (13) are positioned on opposite sides of said at least one hose element (2), outside the reinforcement (5) or the optional outer layer (6) arranged around the reinforcement (5), which two “directional-breaking-force amending” means (13) are held against the hose element (2) by at least one tightening means (14) around the two “directional-breaking-force amending” means (13);

and wherein

the expansion device (1) optionally also comprises an outer pressuring means (12) which is arranged on the outside of and encapsulates said at least one hose element (2) and the two “directional-breaking-force amending” means (13), at least a portion between the coupling connection (8) on the first end (9) of the hose element (2) and the optional second coupling connection (10) on the second end (11) of the hose element (2).

4. Expansion device (1) according to claim 3, wherein each “directional-breaking-force amending” means (13) has a cross section being half cylindrical, triangular, quadratic or a combination thereof, and extends at least a portion along and outside the length of the hose element (2).

5. Expansion device (1) for breaking solid materials, wherein the expansion device (1) comprises at least one hose element (2) comprising:

the reinforcement (5) which is arranged around the inner pressuring means (4);

optionally an outer layer (6) arranged around the reinforcement (5);

and wherein

wherein

the expansion device (1) comprises an outer pressuring means (12) which is arranged on the outside of and encapsulates said at least one hose element (2), at least a portion between the coupling connection (8) on the first end (9) of the hose element (2) and the optional second coupling connection (10) on the second end (11) of the hose element (2),

and wherein

the coupling connection (8) on the first end (9) of the hose element (2), and optionally the second coupling connection (10) on the second end (11) of the hose element (2), is arranged to be connected to a device (15) provided to generate at least one pulse of pressurized medium inflow.

6. Expansion device (1) for breaking solid materials, wherein the expansion device (1) comprises at least one hose element (2) comprising:

the reinforcement (5) which is arranged around the inner pressuring means (4);

optionally an outer layer (6) arranged around the reinforcement (5);

and wherein

said at least one hose element (2) optionally comprises a coupling connection (8) on a first end (9) of the hose element (2), and is blinded on a second end (11) of the hose element (2);

wherein

and wherein

the expansion device (1) is provided to expand inside of the expansion chamber (3) by means of at least one “indirectly expanding” component or mixture by means of a phase transformation of the component or mixture via change in temperature or pressure and/or by means of a chemical reaction.

7. Expansion device (1) according to anyone of claims 3-6, wherein the expansion device (1) comprises at least two hose elements (2).

8. Expansion device (1) according to anyone of claims 1-7, wherein said at least one or two hose elements (2) comprise a coupling connection (8) connected to a coupling (16) on the first end (9) of said at least one or two hose elements (2) and comprise a blind plug (17) on the second end (11) of said at least one or two hose elements (2), the blind plug (17) optionally being connected to a second coupling connection (10).

9. Expansion device (1) according to anyone of the preceding claims, wherein the inner pressuring means (4) and/or the optional outer layer (6) arranged around the reinforcement (5) is made of a polymeric material, such as polyester, polyurethane, rubber, or a combination thereof.

10. Expansion device (1) according to anyone of the preceding claims, wherein the at least one “directional-breaking-force amending” material portion (7) and/or the outer pressuring means (12) is made of a material comprising polymeric materials, polyurethane, rubber, steel, or a composite material, or a combination thereof.

11. Expansion device (1) according to anyone of claims 8-10, wherein the blind plug (17) on each second end (10) of said at least one or two hose elements (2) is provided as a casted blind plug.

12. Expansion device (1) according to anyone of the preceding claims, wherein each end coupling (16) and/or blind plug (17) of each second end (10) of said at least one or two hose elements (2) is flat in design.

13. Expansion device (1) according to anyone of the preceding claims, wherein anyone, two or all of the inner pressuring means (4), the reinforcement (5) and the optional outer layer (6) have a petal-like, elliptical, convex or banana-like shape before pressurization.

14. Expansion device (1) according to anyone of the preceding claims, wherein the material of the outer pressuring means (12) also comprises fibers extending in the longitudinal direction of the expansion device (1).

15. Expansion device (1) according to anyone of claim 5 or 7-14, wherein the device (15) provided to generate at least one pulse of pressurized medium inflow is a cartridge containing at least one explosive component.

16. Expansion device (1) according to anyone of the preceding claims, wherein the outer pressuring means (12) has a circular, diamond-shaped, triangular or cubical cross section in the longitudinal direction of the expansion device.

17. Use of an expansion device (1) according to anyone of claim 1-5 or 7-16, for the breaking or cracking of solid materials by use of a pressurised hydraulic medium.

18. Use according to claim 17, wherein increase of pressure is made gradually and by pulsation.

19. Use of an expansion device (1) according to anyone of claims 6-16, for the breaking or cracking of solid materials by use of at least one “indirectly expanding” component or mixture which expands by means of a phase transformation of the component or mixture via change in temperature or pressure and/or by means of a chemical reaction.

20. Method for the production of an expansion device (1) according to anyone of claims 1-16, the method comprising the following steps:

producing at least one hose element (2) by

applying the reinforcement (5) around the inner pressuring means (4);

optionally applying the outer layer (6) around the reinforcement;

optionally providing the coupling connection (8) on the first end (9) of the hose element (2), optionally also providing the second coupling connection (10) on the second end (11) of the hose element (2);

optionally connecting a coupling (16) or a blind plug (17) to any coupling connection (8, 10);

optionally providing the at least one “directional-breaking-force amending” material portion (7) which is arranged outside the reinforcement (5) or outside the optional outer layer (6); and

casting or vulcanization of the expansion device (1), wherein the outer pressuring means (12) is arranged and casted or vulcanized on the outside of said at least one hose element (2), said outer pressuring means (12) encapsulating said at least one hose element (2), at least up to the optional coupling connection (8) on the first end (9) of said at least one hose element (2), and also encapsulating the optional at least one “directional-breaking-force amending” material portion (7), said outer pressuring means (12) optionally also sealing the first end (9) and/or the second end (11), each by a casted blind plug (17).

21. Method according to claim 20, wherein at least two hose elements (2) are produced and the outer pressuring means (12) is casted or vulcanized to encapsulate the at least two hose elements (2) in one expansion device (1).

22. Method according to claim 20 or 21, wherein at least one part of said at least one hose element (2) is flattened during the application of an increased temperature.

23. Method according to anyone of claims 20-22, wherein a blind plug (17) is provided on the second end (11) of said at least one hose elements (2), by casting or optionally by connection to a provided second coupling connection (10).