BULK MATERIAL CONVEYOR BELT SCRAPER AND
METHOD OF FORMING THE SAME
Cross-Reference to Related Applications
[0001] This application is a continuation-in-part of currently pending U.S. Patent
Application Ser. No. 14/466,574, filed on August 22, 2014.
Statement Regarding Federally Sponsored Research or Development
[0002] Not Applicable.
Appendix
[0003] Not Applicable.
BACKGROUND OF THE INVENTION
Field of the Invention
[0004] The present invention pertains to bulk material conveyor belt scrapers.
More specifically, the present invention pertains to a belt scraper that has a
polymeric portion and a metal base portion. The metal base portion comprises an
opening that extends longitudinally through the metal base portion.
General Background
[0005] Conveyor belt scrapers are used to remove bulk material clinging to
conveyor belts. Belt scrapers are typically provided at the head of conveyor belt
assemblies and most are configured to slideably engage with the moving belt to
thereby scrape clinging material from the belt. As such, belt scrapers continuously
wear and periodically need to be replaced. Thus, the serviceability of belt scraper
assemblies is a major factor in selecting a belt scraper assembly. Likewise, the cost
of replacement scrapers is a significant factor in the selection of belt scraper
assemblies.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to a belt scraper that can be easily
replaced and even cut to length at a job site. Moreover, the belt scrapers of the
present invention can be fabricated efficiently, thereby reducing their cost.
[0007] In one aspect of the invention, a bulk material conveyor belt scraper
comprises a polymeric portion and a metal base portion. The belt scraper extends
longitudinally along a longitudinal axis. The base portion comprises a C-channel
portion and a protrusion that extends along the longitudinal axis. The protrusion
extends outwardly from a corner of the C-channel portion and defines an opening
that extends longitudinally through the base portion of the conveyor belt scraper.
The polymeric portion is attached to at least the protrusion of the base portion.
[0008] In another aspect of the invention, a bulk material conveyor belt scraper
assembly comprises a support member that extends along a longitudinal axis and a
belt scraper. The support member comprises a square opening extending
longitudinally through the support member. The support member also comprises a
longitudinally extending stiffening rib protruding from a corner of the support
member. The belt scraper comprises a base portion having a C-channel. The belt
scraper also comprises a polymeric portion that protrudes outwardly from a corner of
the C-channel. The C-channel of the belt scraper is engaged with and partially
encircles the support member in a manner such that the polymeric portion of the belt
scraper extends opposite the stiffening rib.
[0009] In another aspect of the invention, a method of forming a bulk material
conveyor belt scraper comprises welding a first metal channel to a second metal
channel. The first channel is a C-channel having an exterior corner. The first metal
channel is welded to the second metal channel in a manner such that the second
metal channel bridges over the exterior corner of the first metal channel and forms a
channel passageway bound by the first and second metal channels. The method
further comprises bonding a polymeric material to the second channel after welding
the first and second metal channels to each other.
[0010] In yet another aspect of the invention, a bulk material conveyor belt scraper
comprises a polymeric portion and a metal base portion. The belt scraper extends
longitudinally along a longitudinal axis. The base portion comprises a main channel
portion that forms two parallel opposing engagement surfaces and an intermediate
engagement surface perpendicular to the opposing engagement surfaces. The
opposing engagement surfaces and the intermediate engagement surface are
parallel to the longitudinal axis. The opposing engagement surfaces and the
intermediate engagement surface define a main channel region therebetween and
are configured and adapted to collectively contact three sides of a square portion of
a support member in a manner preventing the belt scraper from rotating about the
support member when such a support member is positioned at least partially in the
main channel region. The base portion also comprises a protruding portion that
protrudes from the main channel portion and away from the main channel region.
The protruding portion is configured and adapted to straddle a corner of the square
portion of the support member when the opposing engagement surfaces and the
intermediate engagement surface of the base portion contact the support member.
[001 1] Further features and advantages of the present invention, as well as the
operation of the invention, are described in detail below with reference to the
accompanying drawings.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0012] Figure 1 depicts a perspective view of a bulk material conveyor belt scraper
assembly.
[0013] Figure 2 depicts a perspective view of the belt scraper of the assembly
shown in Figure 1.
[0014] Figure 3 depicts the locking members of the assembly shown in Figure .
[0015] Figure 4 depicts a side view of the assembly shown in Figure 1 as viewed
parallel to the longitudinal axis of the belt scraper.
[0016] Figure 5 depicts a roll formed version of a support member that is
configured to engage with the belt scraper shown in Figure 2.
[0017] Figure 6 depicts an alternative embodiment of the belt scraper.
[0018] Figure 7 depicts a side view of an assembly of the belt scraper shown in
Figure 6 mounted on the support member shown in Figure 5 as viewed parallel to
the longitudinal axis of the belt scraper.
[0019] Figure 8 depicts a side view of another embodiment of a belt scraper in
accordance with the invention.
[0020] Figure 9 depicts a perspective view of another embodiment of a belt scraper
shown in Figure 8 .
[0021] Reference numerals in the written specification and in the drawing figures
indicate corresponding items.
DETAILED DESCRIPTION
[0022] A bulk material conveyor belt scraper assembly 10 in accordance with the
invention is shown in Figure 1. The belt scraper assembly 0 comprises, among
other things, a belt scraper 12, a support member 14, securing members 16, and a
torsion bar 18.
[0023] The belt scraper 12 is shown by itself in Figure 2. The belt scraper 12
comprises a polymeric portion 20 and a base portion 22. The polymeric portion 20 is
preferably formed of a polyester or polyether material that is over-molded onto the
base portion 22. The polymeric portion 20 is preferably chemically cured rather than
heat cured, although it could be cured in any manner. The belt scraper 12 also
comprises a wear tip 24 opposite the base portion 22. The wear tip 24 is preferably
formed by the polymeric portion 20 of the belt scraper 12 and is configured and
adapted to engage and slide against a moving conveyor belt to remove bulk material
clinging to the belt. Alternatively, the belt scraper 12 may comprise a wear tip insert
(not shown) formed out of a different material, such as a tungsten carbide, which can
be over-molded by the polymeric portion 20. The resilient nature of the polymeric
portion 20 allows wear tip 24 to ride over discontinuities of a typical conveyor belt,
without imparting appreciable rotational oscillation to the base portion 22 of the belt
scraper 12.
[0024] The base portion 22 of the belt scraper 12 is preferably formed of metal.
More preferably, the base portion 22 is formed by welding two channel members of
metal to each other along their lengths. The first channel member 26 is preferably a
standard C-channel having three perpendicular portions. Two of the perpendicular
portions intersect at primary corner 28. The second channel member 30 is
preferably also a C-channel, except having four portions oriented at forty-five
degrees relative to each other. The second channel member 30 preferably straddles
the primary corner 28 of the first channel member 26. Thus, a chevron-shaped
opening 32 extends longitudinally through the base portion 22 of the belt scraper 12
and is bound by the first and second channel members 26, 30 (albeit the crosssectional
shape of the opening could vary depending on the shapes of the first and
second channel members 26, 30). After welding the first and second channel
members 26, 30 to each other, the base portion 22 is then placed partially in a mold
and the polymeric portion 20 is molded thereon. The polymeric portion 20 becomes
adhered to the second channel member 30, and preferably also to the first channel
member 26. Although the base portion 22 of the belt scraper is preferably formed by
welding two C-channel members to each other, it should be appreciated that it could
also be formed via a custom extrusion. It should also be appreciated that the second
channel member 30 can occupy space that otherwise would typically be occupied by
the polymeric portion 20. Thus, the second channel member 30 both torsionally
supports the polymeric portion 20 and reduces the amount of polymeric material, and
therefore material cost, required to fabricate the polymeric portion.
[0025] The support member 14 comprises a tube portion 34 and a stiffening rib 36.
The tube portion 34 preferably has a square cross-section. The stiffening rib 36
preferably extends outwardly from one of the corners of the tube portion 34. In the
embodiment shown in Figures 1 and 4 , the stiffening rib 36 is merely a piece of sheet
or plate material that is welded along the length of the tube portion 34. However, the
tube portion 34 and the stiffening rib 36 can be formed in other ways. For example,
Figure 5 depicts another embodiment of the support member 14' that is roll forged
from an extruded cylindrical tube of material. The stiffening rib 36 increases the
bending stiffness of the support member 14 and is configured to carry primarily
tension. The tube portion 34 is dimensioned to interlock with the first channel
member 26 of the belt scraper 12 as shown such that the support member is able to
exert a torque (about the longitudinal axis of the support member 14) on the belt
scraper to bias the wear tip 24 of the belt scraper against a conveyor belt. The
support member 14 also preferably comprises a plurality of set fittings 38 which,
along with set screws 40, secure the support member 14 to the torsion bar 18.
[0026] As shown in Figure 4, the torsion bar 18 is generally cylindrical but also
comprises an angle iron 42 extending along its longitudinal length. The angle iron 42
is preferably welded to the cylindrical portion 44 of the torsion bar 18 and prevents
rotation between the torsion bar and the support member 14. The set screws 40 of
the support member 14 prevent the support member from sliding longitudinally
relative to the torsion bar 18.
[0027] The belt scraper 12 is secured to the support member by the securing
members 16, which are shown by themselves in Figure 3. Each securing member
16 comprises an opening 46 configured to encircle the support member 14. Each
securing member 16 also comprises a pair of bracing tabs 48 and a locking tab 50.
The bracing tabs 48 are configured to bare against the support member 14 in a
manner preventing the securing members 16 from rocking outboard when the
securing members are locked in place adjacent to the belt scraper 12. The bracing
tabs 48 also make it easier to slide the securing members 16 onto the support
member 14 when assembling the securing members to the scraper assembly 10.
The locking tabs 50 of the securing members 16 are configured to extend into the
opposite ends of the longitudinal opening 32 that extends through the base portion
22 of the belt scraper 12 to thereby secure the belt scraper 12 to the support
member 14. However, the locking tabs 50 of the securing members 16 only loosely
extend into the opening 32 of the belt scraper 12 and therefore the securing
members are not configured to carry the primary belt scraping loads. The primary
belt scraping loads are instead carried by contact forces between the first channel
member 26 of the base portion 22 of the belt scraper 12 and the support member
14. Releasable locking pins 52 preferably extend through the stiffening rib 36 of the
support member 14 to longitudinally secure the securing members 16 in place along
the support member.
[0028] An alternative embodiment of a belt scraper 12' is shown in Figures 6 and
7 . This belt scraper 12' is interchangeable with the belt scraper described above
but has a different base portion 22' that comprises a roll forged portion 54 and a
brace 56. The polymeric portion 20' of the belt scraper 2' is basically the same as
that of the other embodiment. The roll forged portion 54 of the base portion 22' of
the belt scraper 12' is roll formed from flat sheet stock such that it has two opposing
engagement surfaces 58 and an intermediate engagement surface 60
perpendicular thereto that collectively form a C-channel portion and engage three
sides of the square portion 34, 34' of a support member 14, 14'. The rolling also
forms a channeled protrusion 62 configured to extend outward from a corner of
such a square portion of a support member 14, 14' when the belt scraper is
attached thereto. The brace 56 is formed separately and is welded across the
channel portion of the protrusion 62. The brace 56 as shown has undulating side
edges to reduce the amount of material required to form the brace and to maximize
the number of braces that can be cut from a single sheet of material (preferably via
laser cutting). The brace 56 prevents the opposite sides of the protrusion 62 from
spreading apart when the belt scraper 12' is under load. As shown in Figure 7, the
brace 56 is positioned such that the base portion 22' of the belt scraper 12', like the
other embodiment of a belt scraper described above, comprises an opening 32'
extending longitudinally through the base portion that is configured to receive the
locking tabs 50 of the securing members 16.
[0029] Still another embodiment of a belt scraper 12" is shown in Figures 8 and 9 .
That embodiment of the belt scraper 12" is interchangeable with the other belt
scrapers described above but has a different base portion 22" that comprises a
base portion 22" formed partially of the same roll forged portion 54 as the
embodiments shown in Figures 6 and 7. However, instead of also comprising a
brace 56 like that of the embodiment shown in Figures 6 and 7, the base portion 22"
of the embodiment shown in Figures 8 and 9 comprises a rectangular tube 64 that
preferably is welded along two of its edges (the lower ones in Figure 8) to the roll
forged portion 54 inside the channeled protrusion 62. Thus, like the brace 56 of the
second embodiment, the rectangular tube 64 prevents the opposite sides of the
protrusion 62 from spreading apart when the belt scraper 12" is under load and
forms an opening 32" extending longitudinally through the base portion 22" that is
configured to receive the locking tabs 50 of the securing members 16 for securing
the belt scraper 12" to the support member 14. The polymeric portion 20" of the
belt scraper 12" shown in Figures 8 and 9 is the same as that of the belt scraper 12'
embodiment shown in Figures 6 and 7.
[0030] In view of the configurations of the conveyor belt scraper assembly 10 as
described above, it should be appreciated that the belt scraper 12 can be cut to
length from a longer belt scraper and can be quickly replaced when worn.
Furthermore, in view of the foregoing, it should be appreciated that the invention has
several advantages over the prior art.
[0031]As various modifications could be made in the constructions and methods
herein described and illustrated without departing from the scope of the invention, it
is intended that all matter contained in the foregoing description or shown in the
accompanying drawings shall be interpreted as illustrative rather than limiting. Thus,
the breadth and scope of the present invention should not be limited by any of the
above-described exemplary embodiments, but should be defined only in accordance
with the following claims appended hereto and their equivalents.
[0032] It should also be understood that when introducing elements of the present
invention in the claims or in the above description of exemplary embodiments of the
invention, the terms "comprising," "including," and "having" are intended to be openended
and mean that there may be additional elements other than the listed
elements. Additionally, the term "portion" should be construed as meaning some or
all of the item or element that it qualifies. Moreover, use of identifiers such as first,
second, and third should not be construed in a manner imposing any relative position
or time sequence between limitations. Still further, the order in which the steps of
any method claim that follows are presented should not be construed in a manner
limiting the order in which such steps must be performed, unless such an order is
inherent or explicit.

What is claimed is:
1. A bulk material conveyor belt scraper comprising a polymeric portion and a
metal base portion, the belt scraper extending longitudinally along a longitudinal axis,
the base portion comprising a main channel portion that forms two parallel opposing
engagement surfaces and an intermediate engagement surface perpendicular to the
opposing engagement surfaces, the opposing engagement surfaces and the
intermediate engagement surface being parallel to the longitudinal axis, the opposing
engagement surfaces and the intermediate engagement surface defining a main
channel region therebetween and being configured and adapted to collectively
contact three sides of a square portion of a support member in a manner preventing
the belt scraper from rotating about the support member when such a support
member is positioned at least partially in the main channel region, the base portion
also comprising a protruding portion that protrudes from the main channel portion
and away from the main channel region, the protruding portion being configured and
adapted to straddle a corner of the square portion of the support member when the
opposing engagement surfaces and the intermediate engagement surface of the
base portion contact the support member.
2. The bulk material conveyor belt scraper of claim 1 wherein a single piece of
homogeneous metal material forms the main channel portion and the protruding
portion of the base portion.
3. The bulk material conveyor belt scraper of claim 2 wherein an opening
extends longitudinally through the protruding portion of the base portion of the belt
scraper and is encircled by the base portion.
4. The bulk material conveyor belt scraper of claim 3 wherein the base portion
comprises a rectangular tube that is attached internally to the protruding portion of
the base portion and that extends longitudinally parallel to the longitudinal axis, and
the rectangular tube defines the opening.
5. The bulk material conveyor belt scraper of claim 1 wherein a first piece of
homogeneous metal material forms the main channel portion of the base portion, a
second piece of homogeneous metal material forms the protruding portion of the
base portion, the first piece is welded to the second piece, an opening extends
longitudinally through the protruding portion of the base portion of the belt scraper,
and the opening is encircled collectively by the main channel portion and the
protruding portion of the base portion of the belt scrapper.
6. A bulk material conveyor belt scraper assembly comprising:
the bulk material conveyor belt scraper of claim 1; and
a support member extending parallel to the longitudinal axis, at least a portion
of the support member having a square cross-section with four sides, the support
member being positioned within the main channel region of the main channel portion
of the base portion of the belt scraper with the opposing engagement surfaces and
the intermediate engagement surface of the base portion collectively in contact with
three of the sides of the support member in a manner preventing the belt scraper
from rotating about the support member and in a manner such that the protruding
portion straddles a corner of the square portion of the support member.
7 . The bulk material conveyor belt scraper assembly of claim 6 wherein an
opening extends longitudinal through the protruding portion of the base portion of the
belt scraper and is encircled by the base portion.
8. The bulk material conveyor belt scraper assembly of claim 7 wherein the
assembly comprises a pair of securing members, each of the securing members
comprises a locking protrusion and is configured and adapted to slideably attach to
the support member, the locking protrusions of the securing members are configured
to at least partially extend into the opening of the belt scraper from longitudinally
opposite sides of the belt scraper in a manner securing the belt scraper to the
support member.
9. The bulk material conveyor belt scraper assembly of claim 8 wherein each of
the locking members encircles the support member.
10. The bulk material conveyor belt scraper assembly of claim 6 wherein the
support member comprises a stiffening rib that is attached to the portion of the
support member that has the square cross-section, and the stiffening rib extends
longitudinal parallel to the longitudinal axis and protrudes obliquely from a corner of
the portion of the support member that has the square cross-section opposite the
corner of the support member straddled by the protruding portion of the base portion
of the belt scraper.
11. The bulk material conveyor belt scraper assembly of claim 0 wherein an
opening extends longitudinal through the protruding portion of the base portion of the
belt scraper and is encircled by the base portion, the assembly comprises a pair of
securing members, each of the securing members comprises a locking protrusion
and is configured and adapted to slideably attach to the support member, the locking
protrusions of the securing members are configured to at least partially extend into
the opening of the belt scraper from longitudinally opposite sides of the belt scraper
in a manner securing the belt scraper to the support member.
12. A method of forming a bulk material conveyor belt scraper comprising:
welding a first metal channel to a second metal channel, the first channel
being a C-channel having an exterior corner, the first metal channel being welded to
the second metal channel in a manner such that the second metal channel bridges
over the exterior corner of the first metal channel and forms a channel passageway
bound by the first and second metal channels; and
bonding a polymeric material to the second channel after welding the first and
second metal channels to each other.
13. The method of claim 12 wherein at least a portion of the second channel is
partially positioned in a mold and the polymeric material solidifies in the mold in a
manner bonding a polymeric material to the second channel.
14. The method of claim 12 wherein the polymeric material extends over the
second metal channel and is bonded to the first metal channel.
15. The method of claim 2 wherein the conveyor belt scraper comprises a wear
tip that is adapted and configured to slide against a moving conveyor belt and the
polymeric material forms the wear tip.