LINING ELEMENT

Abstract

A lining element includes at least three layers and is configured to be mounted to a structure exposed to wear. The lining element has a wear-impeding polymer layer, an energy-absorbing polymer layer and a reinforcing polymer layer. The reinforcing layer is located adjacent the structure exposed to wear, whereas the energy-absorbing layer is located between the reinforcing layer and the wear-impeding layer. The wear-impeding layer is located on top of the energy-absorbing layer.

Claims

1. A wear-impeding lining element including at least three layers and configured to be mounted to a structure exposed to wear, said lining element comprising a wear-impeding layer comprising a polymer material, an energy-absorbing layer comprising a polymer material and a reinforcing layer comprising a polymer material with at least one reinforcement embedded in the reinforcing layer polymer material, wherein the reinforcing layer is located adjacent said structure exposed to wear, wherein the energy-absorbing layer is located between the reinforcing layer and the wear-impeding layer, and wherein the wear-impeding layer is located on top of the energy-absorbing layer.

2. The lining element according to claim 1, wherein said at least one reinforcement comprises at least one textile sheet.

3. The lining element according to claim 1, wherein said at least one reinforcement comprises a number of overlapping fine-mesh textile sheets.

4. The lining element according to claim 1, wherein the wear-impeding layer comprises a homogenous low friction polymer material.

5. The lining element according to claim 1, wherein the energy-absorbing layer comprises natural or synthetic rubber material.

6. The lining element according to claim 1, wherein the lining element comprises a further layer located between the reinforcing layer and the energy-absorbing layer or between the energy-absorbing layer and the wear-impeding layer.

7. The lining element according to claim 1, wherein the further layer comprises a homogenous polymer material.

8. The lining element according to claim 1, wherein the further layer comprises textile reinforcement.

9. The lining element according to claim 1, wherein the thickness of the wear-impeding polymer layer is about 10-150 mm.

10. The lining element according to claim 1, wherein the thickness of the energy-absorbing polymer layer is about 5-40 mm.

11. The lining element according to claim 1, wherein the thickness of the reinforcing polymer layer is about 5-20 mm.

12. The lining element according to claim 1, wherein the hardness of the wear-impeding polymer layer is about 40-90 Shore(A).

13. The lining element according to claim 1, wherein the hardness of the energy-absorbing polymer layer is about 30-70 Shore(A).

14. The lining element according to claim 1, wherein the hardness of the reinforcing polymer layer is about 65-95 Shore(A).

15. The lining element according to claim 1, wherein the polymer wear-impeding layer comprises reinforcing fillers.

16. The lining element according to claim 1, wherein the lining element is configured to be fastened to the structure exposed to wear by means of bolts.

17. A wear-impeding lining element with at least three layers and configured to be mounted to a structure exposed to wear, said lining element comprising a wear-impeding layer based on a polymer material, an energy-absorbing layer based on a polymer material and a reinforcing layer based on a polymer material, said reinforcing layer being adjacent to said structure exposed to wear, said energy-absorbing layer being sandwiched between said reinforcing layer and said wear-impeding layer, and said wear-impeding layer being placed on top of the energy-absorbing layer.

18. The lining element according to claim 17, wherein the reinforcing layer comprises a homogenous polymer material.

19. A lining system comprising a number of lining elements as claimed in claim 1, said lining elements being arranged to cover areas of a structure which are exposed to wear.

20. A kit comprising a number of lining elements as claimed in claim 1 and a number of fastening bolts.

21. (canceled)

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Embodiments of the invention will be described in the following, reference being made to the appended diagrammatical drawings which illustrate non-limiting examples of how the inventive concept can be reduced into practice.

[0033] FIG. 1 is a schematic, isometric view of a hauler bucket with a lining system attached thereto.

[0034] FIG. 2 is a schematic view of a lining system attached to a side wall of the hauler bucket,

[0035] FIG. 3 is an isometric view of a lining element shown in FIG. 2,

[0036] FIG. 4 is a partial sectional view of the lining element according to an embodiment,

[0037] FIG. 4A is a detail of the lining element in FIG. 4, with two reinforcements,

[0038] FIG. 4B is a detail of the lining element in FIG. 4, with three reinforcements,

[0039] FIG. 5 is a sectional view of the lining element according to another embodiment, and

[0040] FIG. 6 is a top view of a part of the lining system in FIG. 2.

DETAILED DESCRIPTION OF EMBODIMENTS

[0041] Hereinafter, certain embodiments will be described more fully with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of example so that this disclosure will be thorough and complete, and will fully convey the scope of the invention, such as it is defined in the appended claims, to those skilled in the art.

[0042] A hauler truck 30 with a bucket 31 lined with lining plates 1 according to one embodiment is shown in FIG. 1. One of the hauler's 30 side walls 100 is shown in FIG. 2 illustrating an arrangement of lining plates 1. As can be seen, the lining plates 1 have different sizes and shapes depending on their location in the bucket 31.

[0043] In FIG. 3 an isometric view of the multi layer lining or lining element 1 according to one embodiment is shown. In the following, the lining element 1 is also referred to as a wear-impeding member or structure as well as a wear plate. The basic structure of the lining element 1 comprises a combination of three layers 2, 3, 4 of polymer materials.

[0044] First, a reinforcing layer 4 is provided, which, when the lining element 1 is mounted, will be located closest to a surface or foundation 7 to be protected (see FIGS. 4-5). Secondly, an energy-absorbing layer 3 is provided on top of the reinforcing layer 4. Thirdly, a wear-impeding layer 2 is provided on top of the energy-absorbing layer 3.

[0045] The thickness of the lining 1 may vary according to the specific applications. For a light duty application, e.g. gravel, the thickness could be as low as 20 mm and for heavy duty the thickness could be up to 210 mm.

[0046] Through all of the polymer layers 2, 3, 4 longitudinal bores 9 are provided. The number of bores may depend on the size and shape of the lining element 1. The materials, features and functions of the polymer layers 2, 3, 4, as well as the attachment of the wear plate 1 to the foundation 7 will be described in more detail hereinafter in conjunction with FIG. 4 and FIG. 5.

[0047] With reference to FIG. 4, a portion of the lining element 1 of FIG. 3 is shown in cross section. The wear-impeding layer 2 comprises a polymer material with a certain amount of reinforcing fillers which provide the layer 2 with higher wear resistance and an improved breaking strength. An example of reinforcing filler is carbon black. Preferably, the material of the layer 2 is natural rubber or a blend of synthetic elastomers. The combination of the sandwiched multiple layers 2, 3, 4 making up the multilayer polymer lining element 1 results in an efficient product which is improved over prior art in that it is securely attachable to an underlying structure and that it has improved shock absorbing properties thanks to the combination of both a wear layer and an energy absorbing layer.

[0048] Further, the wear-impeding polymer layer 2 may for some applications be treated to have low friction. This is done by mixing a blend of certain chemicals into the rubber mixture. For example, these chemicals may be waxes or oils, e.g. paraffin oil. The low friction chemicals are thus evenly distributed throughout the whole layer 2, making it homogenous. Thus the entire wear layer 2 is friction treated and the friction surface may not be worn off. If the foundation 7 to which the lining element 1 is mounted is e.g. a hauler truck bucket, the load slides off more easily with a friction treated layer 2. Hereby it is possible to avoid heating of the hauler bucket, which otherwise may be necessary in order to make the load slide off.

[0049] The wear-impeding polymer layer 2 may have different hardness due to the application, and preferably the hardness is about 40-90 Shore(A), more preferably the hardness is about 50-75 Shore(A). The hardness of the layer 2 is obtained by the amount of reinforcing fillers, and by the type of filler. In summary, the wear-impeding layer 2 has anti-wear properties and low adhesiveness. As mentioned above, it may also be friction treated. The thickness of the wear-impeding layer 2 is preferably about 10-150 mm. It constitutes approximately 50-71% of the total thickness of the multi layer rubber lining element 1. The total thickness of the lining element 1 is approximately 20-210 mm.

[0050] The energy-absorbing layer 3 comprises a polymer material, preferably a soft natural rubber material. The hardness of the polymer material is preferably in the approximate range 30-70 Shore(A), and more preferably about 30-50 Shore(A). The purpose of the energy-absorbing layer 3 is to absorb energy from load falling onto the lining and to reduce noise. The thickness of the energy-absorbing layer 3 is preferably about 5-40 mm.

[0051] Depending on the application, the energy-absorbing layer 3 may comprise natural rubber (NR) or a mixture of natural rubber (NR) and butadiene rubber (BR). Alternatively, it could comprise NR and styrene butadiene (SBR). Another alternative is to use a combination of NR, BR and SBR. Further options are to exclude NR from the above mentioned combinations and to use a purely synthetic rubber.

[0052] A preferred thickness of the energy-absorbing polymer layer 3 is about 5-40 mm. The energy absorbing layer 3 constitutes approximately 7-30%, more preferably about 10-20%, of the total thickness of the lining element 1.

[0053] As best shown in FIGS. 4A-4B, the reinforcing layer 4 comprises a polymer material in the shape of a composite with reinforcement. Hence, the reinforcing polymer layer 4 is reinforced by at least one sheet of embedded textile 4a comprising a fine-mesh fabric of aramid, polyester, polyamide or similar. The textile reinforcement 4a is constructed by layering fabric and thin layers of rubber. The fabrics are arranged in groups of two. One or more groups of two reinforcement sheets of fabric can be provided in the reinforcing polymer layer 4. In FIG. 4A two groups are shown, i.e. the reinforcement layer 4 comprises four sheets of fabric. In FIG. 4B three groups of fabric are shown, i.e. the reinforcement layer 4 comprises six sheets of fabric. In other embodiments, the number of fabric sheets may vary. For example, one group of fabric sheets may comprise one sheet, or it may comprise three or more sheets. The number of groups of fabric sheets may vary as well, e.g. between 2 and 10, depending on the application and the type of wear the liner is supposed to be exposed to.

[0054] The reinforcing polymer layer 4 has a hardness of about 65-95 Shore(A), preferably about 90 Shore(A), and it is about 5-20 mm thick. Preferably, the reinforcing layer 4 constitutes 5-25%, and more preferably about 7-15%, of the total thickness of the lining element 1. The reinforcing layer 4 could in some applications comprise a homogenous polymer material, or, as an alternative to the textile reinforcement 4a, comprise a thin steel grid, or reinforcing fibers.

[0055] Through the multilayer structure 1 extends the bore 9 which has a slightly larger diameter through the wear-impeding layer 2 and the energy-absorbing layer 3 than through the reinforcing layer 4. A fastening bolt 5 is placed in the bore 9 and the head 5a of the bolt 5 abuts the upper surface of the reinforcing layer 4, i.e. the surface adjacent the energy-absorbing layer 3. The shaft 5b of the bolt 5 extends through the reinforcing layer 4 and into the foundation 7. The diameter of the head 5a of the bolt 5 is slightly larger than the diameter of the bore 9 through the reinforcing layer 4. Above the bolt 5, inside the bore 9, an elongate polymer plug 6 is inserted to cover or fill out the bore 9. Subsequently, the lining element 1 is kept in place by means of the bolts 5.

[0056] Conventional rubber linings are attached by bolts as well, but a problem with these rubber linings is that the rubber is stretchable. The conventional lining element is attached to a structure by a counter-sinked bolt, just as described above. The bolt head rests on the lining element at some level, depending on how far the bolt is counter-sinked. When the lining element is exposed to external stresses, there is a risk that the rubber surrounding the bolt stretches, such that the bolt hole becomes enlarged in such an extent that the bolt head can pass through it. Thus, the lining element becomes detached from the structure it is supposed to protect. In summary, if a lining element comprising a stretchable material is fastened with bolts, the rubber material may be stretched around the bolt and thereby the lining plate may come loose.

[0057] With the lining elements described in this application, one purpose of the reinforcing layer 4 is to improve the attachment of the lining element 1 to the foundation 7, which is e.g. a hauler bucket. Each lining element 1 is attached to the foundation 7 by means of bolts 5, whose heads 5a together with the reinforcement of layer 4 lock the lining plate 1 in place. The reinforcement 4a adds stability to the layer 4 and secures the plate. Thanks to the reinforcing layer 4a it is hardly possible for the rubber of the reinforcing layer 4 to stretch, and thus the bore cannot become enlarged such that the bolt head may pass through it.

[0058] Therefor, conventional linings are often reinforced with metal plates closest to the foundation 7, in order to avoid the problem with stretching rubber and to fasten the plates more easily to the foundation 7. But, in the meantime these linings become very heavy. Further, due to the bottom mounting plate of metal it is not possible to cut a conventional, metal-reinforced lining into smaller pieces after manufacturing in a relatively easy manner. Even if the reinforcement is a metal grid it is difficult to divide the lining pieces into smaller sections with out heavy tools. Thanks to the textile reinforcement 4a of the reinforcing layer 4 of the lining element 1, it is possible to quite easily divide larger pieces of liners into smaller, customized sections. These can be placed like a “mosaic” of pieces to cover areas with complex geometry. This opens up for tailor-made lining assemblies, as well as for the end user to customize a spare lining piece to fit in the place of a worn-out lining element, regardless the shape of the worn-out piece.

[0059] Thanks to the preferred material of the reinforcing layer 4, the weight of the lining element, and thus the total weight of the heavy duty vehicle lined with a system of lining plates 1, can be reduced by up to a tonne. It is thus possible to increase the load of the hauler accordingly, which leads to less transportation and in the end lower fuel consumption and lower emissions. The lower weight also allows for an installation without heavy lifting equipment.

[0060] In FIG. 5, a lining element 11 according to a further embodiment is shown. This lining element 11 comprises a wear-impeding layer 12, an energy-absorbing layer 13 and a reinforcing layer 14 with embedded textile reinforcement 14a, basically corresponding to the polymer layers 2, 3, 4 described in conjunction with FIGS. 4, 4A and 4B. The lining element 11 of FIG. 5 further includes an additional fourth layer 18 provided between the energy-absorbing layer 13 and the wear-impeding layer 12. The additional layer 18 of this embodiment comprises a polymer with reinforcement 18a which preferably is of textile and which protects the energy-absorbing layer 13 from penetration of pointy rocks or other sharp edges hitting the lining 11. The textile reinforcement 18a corresponds to the fabric 4a described in conjunction with FIGS. 4, 4A and 4B. If the lining 11 is hit by a pointy object and the wear-impeding layer 12 is penetrated, the additional layer 18 protects the softer energy-absorbing layer 13 from being penetrated as well. The lining element 11 is attached to the foundation or structure to be protected 17 by a bolt 15, comprising a head 15a and a shaft 15b, extending into a bore 19 in the same way as described in conjunction with the lining 1 in FIG. 4. Accordingly, the bore 19 is covered by a polymer plug 16.

[0061] In one embodiment, the further layer 18 comprises the same material as the reinforcing layer 14. In another embodiment the layer 18 does not comprise textile reinforcement, but a homogenous polymer or rubber layer.

[0062] It is also possible to use more layers than four and the additional layers may be located anywhere in the multilayer layer assembly.

[0063] In FIG. 6 there is shown an assembly of three lining elements 1a, 1b, 1c designed in accordance with an embodiment of the invention. The lining elements 1a, 1b, 1c all have different shapes and sizes in order to match a part of the side wall of the hauler bucket 31 shown in FIGS. 1 and 2. The lining pieces 1a, 1b, 1c are all provided with bores 9, for the bolts to be inserted into. The pieces are delivered to the buyer as a kit of pieces to be mounted on a bucket or the like by the customer. The kit also includes a number of fastening bolts for the attachment of the lining elements. When the user installs the lining to his structure, there is no need for pre-drilling in the structure exposed to wear. The holes are made in the underlying structure at the same time as the individual lining plates are attached. There is thus no need for firstly calculating the positions for the holes in the structure and secondly fit the lining pieces to the predrilled holes.

[0064] It should be appreciated that the inventive concept is not limited to the embodiments described above, and many modifications are feasible within the scope of the invention set forth in the appended claims. For instance the lining system may be installed on any area exposed to wear, e.g. in mining industry, other types of vehicles in addition to haulers, conveyors, chutes, or any other area that needs protection in an exposed environment. The hardness of the layers can vary between different applications—heavy rocks up to 1000 kg/rock require harder materials, whereas softer materials are appropriate for e.g. gravel. The thicknesses of the layers illustrated in the drawings are not to scale, and they may vary according to different applications. Additional layers may be placed anywhere in the multilayer lining, and they may provide the lining with additional features like increased strength, increased wear resistance, lower friction, among other possibilities.