Description:FORM 2
The Patents Act, 1970
(39 of 1970)
&
The Patents Rules, 2003
COMPLETE SPECIFICATION
(Section 10 and Rule 13)
Title Of The Invention
“Interlocked Ceramic Wear Resistant Liner”
APPLICANT
TEGA INDUSTRIES LIMITED,
having registered office at
Godrej Waterside, Tower-II, Office No. 807, 8th Floor, Block DP-5, Salt Lake Sector V, Bidhannagar, Kolkata, West Bengal 700 091, India
The following specification particularly describes the invention and
the manner in which it is to be performed
Interlocked Ceramic Wear Resistant Liner
FIELD OF INVENTION
This invention pertains to an advanced ceramic wear-resistant liner designed for the bulk material handling industry. Specifically, the innovation introduces a mechanically interlocked system for ceramic chute lining, enhancing resistance to wear, impact, and corrosion while offering superior thermal and chemical resilience. The technology is especially effective as a liner in chutes, bins, hoppers, and other material handling equipment, safeguarding the mother plates of the equipment against wear and tear.
BACKGROUND ART
Wear panels are commonly employed in industries like minerals, mining, foundry, milling, and materials handling to extend equipment lifespan, reduce maintenance downtime, and improve throughput. These panels are typically fastened to the floors and walls of various equipment, including chutes, hoppers, bins, tanks, separator devices, fan housings. They serve as protective layers in areas where abrasive or corrosive materials could lead to accelerated wear, ensuring a durable cover or liner in direct contact with substances like crushed rock, coal, ore, grain, and other abrasive aggregates.
In a prior art instance, as outlined in US patent US5055336A, a wear member for chutes handling heavy abrasive materials, such as quarry materials, is disclosed. The design incorporates a mounting plate and at least one sturdy wear-resistant member fixed to the mounting plate, extending longitudinally in the direction of material movement. Additionally, a layer of resilient material, selected from materials like urethane and rubber, is affixed to the mounting plate. Notably, the rigid member extends perpendicularly through both the mounting plate and the resilient layer, securing it to the chute. This arrangement ensures that both the rigid member and the resilient material are fully exposed to the abrasive materials being transported.
In another prior art example, as detailed in PCT patent specification WO2006132582A1, a wear-resistant lining element (1) for a surface prone to wear is disclosed. This surface, intended for the movement of materials like crushed ore and rock particles, features an outwardly directed surface (4). The wear-resistant lining element possesses a thickness (d) and is composed of elastomeric material (2), primarily designed to absorb impact energy, and wear-resistant members (3), mainly engineered to withstand wear. The wear-resistant members (3) are arranged in a plane (P) perpendicular to the outwardly directed surface (4), with an intentional partial overlap in the direction of thickness (d). Furthermore, the invention encompasses a wear-resistant lining composed of multiple such wear-resistant lining elements (1).
In a prior art instance, as outlined in US patent US 2016/0039608 A1, the ceramic blocks (1) interlock by placing them side by side in opposite directions. The protruded part (5) of one block mechanically fits with the depressed part (6) of the adjacent block, creating a secure interlocking arrangement. This mechanism, found along the vertical faces (3) at the front and rear ends, prevents dislodgment during operation. Thin rubber films (7 and 8) between blocks enhance bonding, minimizing the risk of dislodgment. This interlocking design, reinforced by rubber films and chemical bonding, ensures a durable chute liner with improved wear resistance and reduced maintenance downtime.
Steel liners and various composite liners, incorporating materials such as polymers, hardened steel, ceramics, etc., are commonly employed in industrial applications due to their effectiveness. However, these solutions encounter certain limitations. In instances where steel liners are placed in high-impact zones of chutes, where materials initially collide with the chute wall, surface micro-cracks often develop due to the wear caused by high- impact fatigue. Additionally, composite liners, particularly those combining rubber and ceramics, face challenges in high-temperature environments. Consequently,
there has been a persistent need to develop chute wall liners that not only withstand high impact loads and abrasion wear but also exhibit resilience to high temperatures, effectively addressing the demands of such challenging conditions.
An optimal chute liner should effectively withstand both impact and abrasion wear, promote smooth material flow, and minimize material degradation and fines generation
DRAWBACKS OF PREVIOUS INVENTION
These panels exhibit certain drawbacks, such as high manufacturing costs, the need for specialized tools for fabrication and assembly. Relying on rubber substrates to bond different sections of wear panels together presents various challenges in the assembly process. This approach can lead to extended lead times and is susceptible to issues such as delamination and cracking.
Encapsulating ceramic wear members in polyurethane or rubber may lead to delamination, and processes like hot moulding rubber can cause thermal shock, potentially damaging the ceramic or other wear components. Additionally, bonding ceramics to other wear materials can be a complex and unreliable process.
OBJECT OF INVENTION
1. The primary goal of this invention is to offer an advanced wear liner characterized by extended wear life and exceptional resistance to impact, and abrasion. This innovation is specifically designed for utilization in the mining and material handling industries, addressing the rigorous demands of these sectors with enhanced durability and protective capabilities.
2. In addition to its primary objectives, another key aim of the wear liner is to deliver
effective thermal resistance, particularly in applications where high heat zones are prevalent. This feature ensures the wear liner can withstand and protect against elevated temperatures, expanding its utility in environments with demanding thermal conditions.
3. Another aim of the invention is to furnish a wear liner characterized by a cost- effective manufacturing process and diminished expenses for spare parts.
4. Another objective of the invention is to present wear panels that significantly minimize the likelihood of wear member dislodgement, particularly when ceramics are employed, enhancing the overall stability and effectiveness of the system.
SUMMARY OF THE INVENTION
The current invention introduces wear liners specifically designed for use in the mining and bulk material handling industries. These liners are intended to be affixed to the main plate of equipment involved in handling bulk materials, such as transfer chutes, hoppers, bins, silos, and similar processing equipment. The wear liner comprises two crucial components, both possessing resistance to heat and abrasion: a metallic matrix and embedded ceramics.
In particular, the wear liner includes a plurality of ceramic blocks situated within the metallic housing matrix, with the ceramics being intricately interlocked. The mechanical interlocking of ceramic matrices is further reinforced by their connection to the housing matrix through a longitudinal member, ensuring a secure attachment. This interlocking mechanism effectively prevents the inadvertent dislodgement of ceramic matrices from the metallic housing or matrix.
The wear liner's ability to withstand high temperatures, coupled with its resistance to abrasion, proves advantageous in the challenging operational
conditions of bulk material and mineral processing industries. Notably, the absence of polymers or rubber in the bonding process between ceramics and the frame eliminates concerns related to heat degradation. Instead, a thin layer of ceramic resin or putty is utilized between the ceramics and housing matrix. Additionally, the liner is coated with putty to enhance its thermal resistance.
In accordance with preferred embodiments of the said wear liner of the present invention:
-said wear liner comprises of abrasion, corrosion and heat resistant zones with robust design.
-said wear liner can be separated into two or more units.
-said wear liner is made up of metallic matrix herein said as reinforcement for placement of ceramic and other one is the ceramic section which is fitted inside the metallic matrix.
-said metallic matrix (reinforcement section) and the ceramic section are to be attached to each other and metallic strips are inserted to seal the ceramic inside the matrix assembly.
-said metallic matrix (reinforcement section) is made of anyone of or a combination of metal like mild steel, stainless steel and their alloys in proper proportions.
-said wear liner is fitted inside the mineral and bulk material handling equipment (like transfer chutes, hopper, silo, bin, bunker and similar related equipment) by bolting or any different fixing arrangements as per requirements.
Described herein is a wear and impact-resistant liner designed for enhanced durability, consisting of interlocked wear-resistant ceramic blocks of various sizes tailored for specific applications. The liner is distinguished by:
• Metallic Frame/Housing:
A robust metallic frame or housing is provided, complete with side plates specifically designed to accommodate the interlocked wear-resistant ceramic blocks.
• Mechanical Interlocking:
The wear-resistant ceramic blocks are mechanically interlocked within the frame, ensuring a secure and stable arrangement.
• Reinforcement Structure:
The metallic frame/housing is further reinforced by a plurality of metallic bars/strips strategically placed along the adjoining surfaces. This reinforcement mechanism serves to fortify the entire assembly, effectively holding the ceramic blocks in position.
• Integrated System:
The combined structure, incorporating the metallic frame, interlocked ceramic blocks, and reinforcing bars, functions as an integrated system. This system is specifically engineered to withstand the forces generated during material transfer processes.
• Application Versatility:
The liner is adaptable for use in various equipment such as chutes, hoppers, bins, etc., providing an extended lifespan to the equipment by effectively mitigating the impact and wear associated with material transfer.
In summary, the wear and impact-resistant liner described here offers a comprehensive solution by combining wear-resistant ceramic blocks, a sturdy metallic frame, and reinforcing elements. This integrated system significantly enhances the durability of equipment subjected to material transfer processes, making it an effective choice for improving the overall
lifespan of industrial components.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
FIG 1 illustrates the plan view of the Wear liner in accordance with the present invention;
FIG 1(a) illustrates the sectional view BN-BN of the wear liner by taking a section along the Centre as shown in FIG 1 in accordance with the present invention;
FIG 1(b); illustrates the sectional view BM-BM of the wear liner by taking a section along the Centre as shown in FIG 1 in accordance with the present invention;
FIG 2 showcases the isometric view of the liner, featuring multiple rows of profiled ceramics, in accordance with the present invention;
FIG 3 illustrates the isometric view of metallic matrix with profiled side plates in accordance with the present invention;
FIG 4 illustrates the Isometric view of the ceramic blocks in accordance with the present invention;
Figure 4a is a side view of two ceramic blocks interlocked with each other as in the figure 2 in accordance with the present invention;
Figure 4b is a side view of a group of several such ceramic units shown in figures 2 and 4a in accordance with the present invention;
Figure 4c is a side view of a complete ceramic assembly of a particular row of the liner shown in figures 2 and 4a in accordance with the present invention;
Figure 5 presents an isometric view of an alternative design of ceramic units, as depicted in figure 2, aligning with the principles of the present invention;
Figure 5a is a side view of ceramic block interlocking with each other in as shown in fig 2 in accordance with present invention;
Figure 6 illustrates the plan view of wear liner assembly in accordance with the present invention;
Figure 7 illustrates the plan view of wear liner assembly with layer of ceramic putty in accordance with the present invention;
Figure 8 illustrates the fixing arrangement of the mother plate and metallic frame using countersunk (CSK) screws, Nylock nuts, and flat washers;
Figure 8(a) illustrates a detailed view of the fixing arrangement, showcasing the specific details and components involved in the attachment or securing process.
DETAILED DESCRIPTION
The subsequent depiction of preferred embodiments of the present invention is intended solely for elucidating the performance characteristics, without imposing any limitations. The fundamental structural attributes of the wear-resistant liner, as delineated in the earlier sections, and the associated benefits will be expounded upon in the following description, complemented by reference to the accompanying illustrations.
Throughout the drawings, identical reference numerals are employed to designate analogous features. Terms such as "front," "rear," "top," "lateral," "isometric," and similar expressions should be interpreted in relation to the orientation of the chute liner in practical usage.
This clarifying exposition aims to provide a comprehensive understanding of the invention's functionalities and advantages, enhancing the clarity of its constructional features through visual reference in the accompanying drawings.
The present invention introduces a material processing apparatus designed for applications in mining and mineral beneficiation industries. The equipment is equipped with multiple wear liners, each comprising essential components that is metallic frame functions as a reinforcing element, providing structural support to the liner, ceramic section imparting high-level of wear resistance to enhance
its performance and the layer of ceramic putty is strategically placed between the metallic frame and ceramic matrix, contributing to the overall durability of the liner.
Additionally, the ceramic liner is coated on the top with an extra layer of ceramic, further enhancing its wear-resistant capabilities. This innovative design is tailored to meet the demands of material processing in rigorous industrial settings, particularly in mining and mineral beneficiation operations. The liner can be installed on an equipment (example: chute, hopper, bins etc) to protect the mother plate from wear during operation.
The liner includes a metallic frame or housing with cavity and side plates on two sides. The cavity extends along the length or breadth of the metallic frame or housing. The wear liner also comprises of a wear resistant item with different shapes, as herein described, such that they interlock with each other as well as with the metallic housing, as herein described, when inserted into the cavity, to form a wear resistant liner. The reinforcement section is the bottom portion of said liner and said ceramic section is the top portion of said liner and ceramic cushion can be in the middle part, said reinforcement section and said ceramic section are separate units. These are further assembled and installed for ensuring smooth functioning of material processing operation.
The discussed liner integrates a ceramic assembly within a metallic matrix comprising a base plate, non-profiled side plate, and profiled side plate. As shown in figure 3, these side plates are meticulously positioned and welded to the base plate, forming a cohesive structural unit. Notably, two of these plates are profiled, featuring slots through which a mechanical rod (3), is inserted. This mechanical rod is strategically placed through the slots of the profiled side plates, effectively securing and locking the ceramic assembly within the metallic matrix. This innovative design ensures a robust and reliable connection between the ceramic components and the surrounding metallic structure, as depicted in the accompanying figures.
Within the ceramic blocks, there exists an extruded and protruded part, as illustrated in Figure 4. In Figure 4a, it is depicted that these ceramic blocks are intricately interlocked with each other, forming a cohesive and integrated structure. This entire ceramic assembly is securely held within the metallic matrix, as showcased in Figure 4c. To reinforce and maintain the structural integrity of the complete assembly, mechanical rods are introduced, as indicated in the description. These mechanical rods play a crucial role in locking and retaining the configuration of the entire assembly, ensuring a durable and stable construction. The interplay of extruded and protruded features, interlocking ceramic blocks, and the integration with the metallic matrix, along with mechanical rod reinforcement, collectively contribute to the robust design and functionality of the presented structure.
It's important to emphasize that the wear liner is designed with the flexibility to incorporate multiple rows of ceramic blocks. The specific shape and radius of curvature of the interlocking profile on these ceramic blocks may vary from what is depicted in the drawing. This variability allows for adaptability to different requirements and applications.
Furthermore, the number of grooves present in the interlocking profiles of both the metallic matrix and the ceramic blocks is not fixed; it can vary based on specific design considerations. This feature allows for customization and optimization of the wear liner according to the intended use and performance requirements, offering versatility in the arrangement and interlocking mechanisms.
In essence, the wear liner design is adaptable, allowing for modifications in the shape, radius, and number of interlocking features to meet diverse needs in various industrial applications.
The invention introduces composite liners comprising interlocked ceramic blocks embedded within a metallic frame and fixed on the layer of ceramic putty. This lining arrangement enhances resistance to wear and heat, leading to an extended
usable life compared to conventional liners. The incorporation of a metallic frame, interlocked ceramic blocks, and ceramic pads creates a robust and durable system.
One notable advantage of this proposed liner system is its facilitation of straightforward part replacement in the event of wear or damage. This feature minimizes plant downtime, providing a practical and efficient solution for maintenance. The composite liner not only offers enhanced durability but also contributes to operational efficiency, making it a valuable advancement in liner technology for various industrial applications.
Additionally, Figure 4 highlights the vertical faces (4c) at the lateral ends of the block (4), which are plane surfaces. These surfaces contribute to the overall structure and interlocking capability of the ceramic block. Importantly, the figure also illustrates that each block (4) possesses a distinct top surface and bottom surface, further emphasizing the specific orientation and configuration of these interlocking ceramic units. The detailed features depicted in Figure 4 contribute to the comprehensive understanding of the intricacies involved in the interlocking profiles and overall design of the ceramic block unit.
In the arrangement depicted in Figure 4c, it becomes evident that a multitude of ceramic blocks (4), are arranged side-by-side. In this arrangement, the triangular tip or notch of one block is inserted into the groove face of the second adjacent block, facilitating mechanical interlocking between the blocks. This intricate interlocking mechanism is a crucial aspect within the scope of the present invention, contributing to the overall stability and durability of the composite structure. The synergy of the metallic matrix, ceramic blocks, and mechanical rods exemplifies the innovative and robust design of the proposed system.
In the assembly depicted in Figure 4, the ceramic blocks are strategically positioned side by side but in opposite orientations. This intentional arrangement guarantees that the raised section of one block seamlessly interlocks with the recessed portion of the adjacent block. The elevated part of
the first ceramic block is intricately shaped to perfectly match and mechanically engage with the depressed section of the second block, and vice versa. This precise interlocking mechanism, operational between any pair of neighbouring blocks, results in a secure and snug fit, effectively averting any possibility of dislodgment during the course of operation.
Figure 5 illustrates an alternative arrangement of ceramic blocks tailored to meet specific application requirements. Notably, the depicted configuration features increased thickness, aimed at enhancing wear life and endowing the liner with the capability to withstand high impacts. This design adaptation reflects a strategic approach to optimizing the wear liner for enhanced durability and impact resistance in its intended use.
As depicted in Figure 6, the comprehensive wear liner assembly comprises a metallic matrix constructed from a preferred material such as steel. This matrix incorporates profiled ceramic blocks and profiled side plates. Notably, in this specific design, there is an absence of a rubber film between the ceramic and metal components. The metallic matrix is designed with slots at the base to facilitate the fixation of the side plates, creating a secure and integrated structure.
In Figure 7, the wear liner assembly is depicted in the plan view, demonstrating the attachment method using welded studs, nuts, and bolts. Two sectional views provide a closer look at the internal structure: Section BM-BM, shown in Figure 7(a), is obtained by passing a plane through the canter along the length of Figure 7. Section BN-BN, illustrated in Figure 7(b), is acquired by passing a plane along the length through a row of ceramic blocks.
These sectional views offer detailed insights into the internal arrangement and fixation method of the wear liner assembly. The absence of a rubber film, along with the specific sectional perspectives, facilitates a clear understanding of the construction and design features of the presented wear liner system.
Moreover, Section AY-AY, obtained by passing a plane along the length of Fig 7 through a row of Ceramic Blocks, is presented in Fig 7(a). In this section, Ceramic Putty (2) is strategically applied to enhance heat resistance. The Ceramic Assembly, as depicted in Figure 4(a), assumes a crucial role in the overall functionality of the wear liner assembly, adding to its durability and efficiency.
To reinforce the structural integrity, metallic rods (3) are strategically placed on both sides. These rods play a crucial role in preventing the ceramics from dislodging from the metallic matrix, ensuring the overall stability and integrity of the assembly. The comprehensive design incorporates a combination of ceramic elements, ceramic putty coating, metallic rods, and fixing mechanisms. This holistic approach significantly enhances the durability and efficiency of the wear liner assembly across a range of applications. The application of ceramic putty over the liner assembly specifically contributes to improved thermal efficiency, adding another layer of functionality to the overall design.
Figure 8 presents a depiction of the fixing arrangement involving the mother plate and the metallic frame. This is achieved through stud welding at the back of the wear plate, utilizing nuts and flat washers. Additionally, as per specific requirements, an alternative fixing method is showcased, involving bolts, flat washers, and nylock nuts. This versatile approach allows for adaptability based on the specified needs of the application or installation.
While the preceding description of the present invention has been provided with reference to specific embodiments and applications, it is important to note that these examples are presented for illustrative purposes and description. The intention is not to provide an exhaustive or restrictive account of the invention. Instead, the embodiments and applications have been chosen and described to effectively illustrate the underlying principles of the invention and demonstrate its practical applications.
The goal is to offer insight into the inventive concepts and facilitate an understanding of how these principles can be applied in various contexts. It is essential to recognize that the embodiments and applications disclosed are not intended to limit the scope of the invention exclusively to those examples.
COMPONENTS OF LINER
1- Base plate
2- Ceramic putty /ceramic resins
3- Metallic rod
4- Non profiled side plate
5- Profiled side plate
6- Metallic strip
7- Ceramic (25)
8- Ceramic (40)
7(a)/8(a)- Protruded ceramic profile
7(b)/8(b)- Extruded ceramic profile
7(c)/8(c)- flat surface/ Direct contact ceramic profile
The selection and description of specific embodiments and applications aim to provide a clear illustration of the invention's principles, enabling individuals with ordinary skill in the art to implement the invention in diverse embodiments and with various modifications suited to specific use cases. As such, any changes, modifications, variations, or alterations that fall within the scope of the invention, as determined by the appended claims, should be considered as being within the rightful scope of the present invention. This interpretation should align with the broad and fair entitlement to the scope of the invention as defined by the claims. , C , Claims:WE CLAIM
1. A wear and impact resistant liner comprising of :
a plurality of interlocked wear resistant ceramic blocks, characterized in that –
a metallic frame / housing including side plates configured for accommodating the corresponding mechanically interlocked wear resistant ceramic blocks within said frame;
a plurality of Metallic bars / strips disposed along respective adjoining surfaces such that the said metallic frame / housing acts as a reinforcement to hold the said ceramic blocks in position such that the entire assembly along with the side plates becomes an integrated system to withstand the resultant forces due to material transfer process.
2. The wear and impact-resistant liner, as claimed in claim 1, wherein said interlocked wear- resistant ceramic blocks arranged in a manner where the protruding section of one ceramic block seamlessly interlocks with the recessed portion of adjacent ceramics.
3. The wear and impact-resistant liner, as claimed in claim 1, wherein the entire ceramic assembly is structured to securely lock onto the metallic housing;
wherein said locking mechanism is facilitated by a rod or bar, specifically positioned to pass through the depressed sections of the specially designed ceramics; and
wherein the said rod or bar is affixed to the metallic housing, thereby effectively preventing any dislodgement of ceramics from the metallic housing or matrix.
4.The wear and impact-resistant liner, as claimed in claim 1, further includes a securing mechanism where the ceramic assembly is fastened to the metallic housing with said metallic strip is positioned above the protruding sections of the ceramics; and
wherein, a ceramic putty is strategically applied between the metallic frame and the ceramic matrix which serves a dual purpose by enhancing heat resistance and reinforcing the strength of the liner.
5. The wear and impact-resistant liner as claimed in claim 2, wherein the said protruded sections and depressed parts are configured as triangular or circular notches and corresponding triangular or circular grooves, respectively.
6. The wear and impact-resistant liner as claimed in claim 2, wherein the said protruded sections and depressed parts are configured as rectangular notches and corresponding rectangular grooves, respectively.
7. The wear and impact-resistant liner as claimed in claim 1, wherein the said wear and impact-resistant liner involves the insertion of ceramic blocks within the metallic frame;
wherein the profile channel is configured to facilitate automatic locking of the depressed and protruded profile features of the blocks inside the corresponding protruded and depressed features within the cavity; and
wherein additionally, two side plates are introduced at the two ends of the said liner in order to prevent any dislodgement of the blocks during operation, ensuring the stability and integrity of the liner.
8. The wear and impact-resistant liner as claimed in claim 7, wherein the said wear and impact-resistant liner specifies that the metallic frame is constructed from materials preferably iron, steel, aluminium, or their alloys, in order to meet operational and application requirements.
9. The wear and impact-resistant liner as claimed claim 1, wherein the said wear and impact-resistant chute liner includes multiple mechanically interlocked ceramic blocks and the said interlocked ceramic blocks are situated within said metallic frame or housing, which includes side plates; and
wherein a plurality of metallic bars or strips are strategically positioned within the said liner assembly.
10. The wear and impact-resistant liner as claimed in claim 9, wherein the said wear and impact-resistant chute liner describes vertical faces at the front and rear ends of each ceramic block and said faces feature a contour consisting of a protruded part and a depressed part;
wherein said vertical faces at the lateral ends of each block are flat or planar surfaces and the blocks are joined along the vertical faces at the respective front and rear ends, as well as along the vertical faces at the lateral ends; and
wherein each of the protruded part of one block securely receives the depressed part of another block, establishing a mechanical interlocking mechanism between the blocks.
(Pawan Kumar Maheshwari)
IN/PA-761
For Tega Industries Limited
(This application is digitally signed)