PRI ORI TY DETAI LS

[0001 ] The present application claims priority from basic Australian patent application AU 2020900479, filed on 20 February 2020, the entirety of which is incorporated herein by reference.

TECHNI CAL FI ELD

[0002] The present invention relates generally to the field of to the field of mining and ore processing equipment, and more particularly to the field of equipment and components receiving impacts from ore and rock, and providing impact-resistant and wearable surfaces for such equipment and components.

BACKGROUND

[0003] Material transport, processing and comm inution, typically referring to the transport, processing and comminution of mineral-bearing and/or ore- bearing rock and ground material, requires that the machinery, tools and equipment (broadly referred to hereafter as equipment) are able to withstand high volumes of rock and ore, and therefore the equipment must typically be rugged. However, equipment used in mining and processing industry still requires regular maintenance to replace worn components, repair broken ones, and otherwise ensure that the processing train operates smoothly.

[0004] The moving material induces significant impact forces upon the machinery. One such example is at the opening of an ore delivery chute, being the entry point for m ined material into the processing train. Other examples are the exit points of the various processing machinery, such as the exit of a rock crusher.

[0005] Impact panels are a particular component of processing trains that are used in various locations, such as at or around screening machinery, crushers, and around transport conveyor belts. The purpose of the impact panel is to absorb and disperse the force of falling/moving rock and ore. Prior art impact panels are typically made out of a tough elastomer such as vulcanised rubber mounted onto a steel base. The elastomer provides the force absorption, while the steel base merely provides mounting and rigidity. However, the rubber would wear away, thus defining the lifespan of the prior art impact panel.

[0006] One prior art means of increasing the lifespan of a prior art impact panel comprised embedding a reinforcing insert, comprising metallic pellets or ingots, into the panel. The reinforcing insert wore at a slower rate, and so increased the lifespan of the prior art impact panel. However, the embedded metallic elements are prone to fracturing and ‘shedding’, wherein either chunks of the metallic element, or the entire metallic element itself, would become detached and would enter the ore processing stream. This is distinct and separate to the natural and expected wear and tear wherein the tool or machinery surface is gradually removed as fine particulate rather than in distinct pieces. As the metallic blocks P-12 are typically designed to be extremely tough and hard, the presence of chunks of these blocks in the ore processing stream could damage downstream equipment - as the skilled person will appreciate, the machinery in a material processing train is designed to process rock and ore, not pieces of comparatively harder metals that are specifically formed to resist impacts.

[0007] One example of a prior art reinforcing insert P-10 is depicted in Figure 1 , comprising metallic wear blocks of P-12, in one of a range of possible shapes of prior art wear blocks, welded onto a support mesh P-14. The intent of the support mesh P- 14 was to provide a mount for the wear blocks P- 12, and thereby reduce or ameliorate the shedding. Ultimately the prior art attempt to alleviate shedding was unsuccessful, as the support mesh was found to be highly likely to fail at the mounting sites under the repeated impacts endured in ore processing. In addition, the spacing between wear blocks P- 12 (Figure 1 is not to scale) enabled impacts of rock and ore to the sides of the wear blocks, which exacerbated the failure rate of the joints between the wear blocks and support mesh P- 14.

[0008] There is therefore a need for providing an impact panel offering an improved lifespan with reduced chipping and/or shedding, as well as overcom ing or at least ameliorating the deficiencies in the prior art. Dl SCLOSURE OF THE I NVENTI ON

[0009] I n a first aspect, the present invention relates to an impact wear panel comprising an elastomeric panel body, and a plate insert positioned within the panel body, the plate insert comprising at least an impact plate having an upper side and an underside, wherein the impact plate is positioned at a non-zero height within the panel body and is entirely enclosed therein.

[0010] I n an em bodiment, the impact plate com prises at least one opening vertically extending therethrough, the opening being cut, reamed, bored or otherwise formed into the impact plate, and the panel body extends through the at least one opening.

[001 1 ] I n an em bodiment, the at least one opening extends in a horizontal dimension and the at least one opening is oriented on the impact plate so that the dimension is non-parallel to a direction of material flow across the impact wear panel. I n an embodiment, the at least one opening extends in a horizontal dimension, and the at least one opening is oriented on the impact plate so that the dimension is non-perpendicular to a direction of material flow across the im pact wear panel.

[0012] I n an embodiment, the at least one opening horizontally extends across the im pact plate in a direction, and the opening is shaped to form a wave-like, oscillating or substantially sinusoidal curve across its length, each oscillation or wave of the curve extending perpendicular to the direction. I n an embodim ent, the direction is parallel to a direction of m aterial flow across the impact wear panel.

[0013] I n an em bodim ent, the impact plate comprises one or more of a ceram ic, metal, m etal alloy and combinations thereof. I n an embodiment, the impact plate comprises a ceram ic, and the ceramic is a carbide. I n an em bodim ent, the carbide is m icro-alloyed with one or more of m olybdenum , niobium , nickel, vanadium , tungsten, titanium , cobalt and iron. I n an em bodim ent, the impact plate comprises an upper wear layer and a lower support layer, the wear layer being formed from a wear material selected for high toughness and impact resistance, and the support layer being formed from a substrate material selected from suitable substrates that are compatible with the wear material of the wear layer and with the panel body. I n an embodiment, the wear layer of the impact plate comprises an aperture extending therethrough and terminating at the support layer, and the plate insert further comprises a wear indicator configured to indicate that the wear layer is substantially worn, the wear indicator being positioned within the aperture.

[0014] In an embodiment, the impact plate has a variation in vertical thickness across a horizontal dimension thereof. I n an embodiment, the impact plate comprises an upper wear layer and a lower support layer and the variation in vertical thickness is at least partially provided by variation in vertical thickness of the upper wear layer of the impact plate.

[0015] In an embodiment, the plate insert comprises a plurality of impact plates. I n an embodiment, at least one of the plurality of impact plates has at least one impact plate edge that is shaped to form a wave-like, oscillating or substantially sinusoidal curve across its length. I n an embodiment, at least two of the plurality of impact plates are arranged in a vertical stack within the panel body, and the plate insert further comprises spacers extending between the or each sequential pair of impact plates within the vertical stack.

[0016] In an embodiment, there are a plurality of plate inserts within the elastomeric panel body, each plate insert separately comprising an impact plate and an impact plate stand.

[0017] In an embodiment, the impact panel is a screening impact wear panel.

[0018] In a second aspect, there is provided a method of constructing an impact wear panel, the impact panel comprising an elastomeric impact panel body and a plate insert comprising an impact plate having at least one opening vertically extending therethrough, the method comprising the steps of:

1. forming the impact plate by cutting a sheet of wear material, and cutting the at least one opening; 2. positioning the impact plate within a mould of the impact panel body at a predeterm ined depth; and

3. injecting, pouring, casting or otherwise form ing the impact panel body within the mould, such that the impact panel body encapsulates the impact plate and extends through the at least one opening; wherein the panel body contacts both an upper surface and a lower surface of the impact plate, and predeterm ined depth is determ ined as a function of a target lifespan of the impact panel, and at least one operating condition of the im pact panel.

[0019] I n an embodiment, the im pact plate comprises an upper wear layer and a lower support layer.

[0020] I n an embodiment, the at least one operating condition includes at least one of: an initial thickness of an upper portion of the impact panel body; an initial thickness of the im pact plate; an average volum etric and/or mass flow rate of material at an installation site of the impact panel in the ore processing train ; an average density of material at the installation site; an average hardness of m aterial at the installation site; an average size and/or size range of material at the installation size; and an average impact force exerted by material at the installation site. I n an embodiment, the initial thickness of the impact plate is an initial thickness of the upper wear layer.

[0021 ] I n an embodiment, the step of positioning the impact plate at the predetermined depth comprises the steps of:

1 . attaching at least one stand having a length corresponding to the predetermined depth to an underside of the impact plate; and

2. positioning the im pact plate within the mould, such that the stand supports the impact plate at the predeterm ined depth.

[0022] Further em bodim ents of the invention may become apparent through the disclosure contained herein. These embodiments are considered to also fall within the scope of the present invention. DESCRI PTI ON OF FI GURES

[0023] Embodiments of the present invention will now be described in relation to figures, wherein:

Figure 1 depicts a prior art reinforcing element for a prior art panel;

Figure 2 depicts an embodiment of the wear panel of the present invention; Figures 3-7 depict various embodiments of the impact plate of the present invention ;

Figure 8 depicts a side-on view of an embodiment of the impact plate of the present invention;

Figure 9 is an explanatory diagram of differing impact forces across machinery; and

Figures 10-12 depict various embodiments of the present invention having multiple impact plates.

DEFI NI TI ONS

[0024] As used herein, the term ‘lifespan’ refers to the length of time that a tool, a machine, a component or a piece of equipment remains in operational condition. An item ’s lifespan is reached once general wear and/or damage accumulates to a particular threshold level. This level may, by way of non limiting example, be based upon the item’s ability to function and/or its potential for failure. The lifespan of a particular impact wear panel (either prior art or an embodiment of the present invention) may be dictated in various manners depending upon installation site and a range of factors.

[0025] As used herein, the term ‘shedding’ refers to a portion of a tool, equipment or machinery fracturing, with the fractured portion becom ing free to move as a distinct piece and to potentially enter the material being moved or processed and/or damage other machinery downstream. This is distinct and separate from general wear, wherein the tool or machinery surface is gradually removed as fine particulate rather than in distinct pieces.

[0026] As used herein, the term ‘ore processing train’ is not to be construed in the strict sense as referring to an entire processing train from crusher, through screens, grinders, mills and extraction vessels such as leaching tanks and furnaces. Rather, the term ‘ore processing train’ should be construed as encompassing not only the complete train but also a sub-train, a particular branch of a processing train, or a particular zone, machine or piece of equipment within the processing train.

[0027] As used herein, directional terms such as ‘horizontal’ and ‘vertical’ are to be interpreted as being in reference to orientation of the component being referred with respect to the impact panel only. Unless otherwise specified, such directional terms are not to be interpreted as defining the orientation of the impact panel with respect to the environment it is used in.

DETAI LED DESCRI PTI ON OF PREFERRED EMBODI MENTS

[0028] In a first aspect, the present invention comprises an impact wear panel 100 for use in material transport, processing and comm inution, comprising an elastomeric impact wear panel body and a reinforcing insert. The reinforcing insert is a plate insert that comprises at least an impact plate, with the impact plate being positioned at a non-zero height within the panel body and being entirely enclosed therein.

[0029] As used herein, the term “plate” or should be construed as describing an article that is formed as a sheet, and has a length and width that are substantially larger than the thickness of the article - although the length and width may also substantially differ from one another. Holes or apertures may be formed therein or therethrough, and the plate may vary in length, width and/or thickness. A plate may comprise multiple layers of material. The skilled person will appreciate that, by way of non-lim iting example and with reference to Figure 1 , a prior art reinforcing insert P-10 comprising an open mesh support substrate P- 14 with blocks, studs or other individual units of hard metal reinforcement P- 12 welded or otherwise affixed thereto does not constitute an “impact plate”.

[0030] In an embodiment and with reference to Figure 2, the impact wear panel 100 may comprise an elastomeric impact wear panel body 102 and a plate insert 104, wherein the plate insert 104 comprises at least an impact plate 106. In an embodiment, the plate insert 104 is positioned within the impact wear panel body 102 such that the panel body 102 substantially surrounds and encapsulates the impact plate 106 of the plate insert, with the material of the panel body contacting against both an upper side and an underside of the impact plate 106, such that the panel body 102 may be considered to comprise an upper region of the panel body 102A and a lower region of the panel body 102B. The skilled person will appreciate that this should not be necessarily interpreted to mean that the panel body comprises two separate and/or separable halves.

[0031 ] Without limiting the scope of the invention through theory, it is considered that providing a portion of the panel body 102 underneath the impact plate 106 provides various benefits. For example, an elastomeric material may act as a ‘shock absorber’ - once the upper region 102A is worn down and the impact plate 106 is taking direct strikes, the transmission of the impact force through the impact plate 106 and into underlying machinery can be mitigated, attenuated or otherwise reduced by the lower panel body region 102B. In this manner, the impact plate 106 may protect and armour the lower region 102B from degradation, while the elastomeric material of the lower region 102B acts to at least partially absorb the impact force

[0032] In use, the impact wear panel 100 receives impacts from moving material. The impact wear panel body 102 is worn away over time until an upper surface of the impact plate 106 is exposed, whereupon the impact plate 106 receives impacts and is itself worn away. As the skilled person may appreciate, by utilising a plate structure as a reinforcing element for the impact wear panel 100, one may avoid “shock wear” in the form of chipping or shedding. By avoiding substantial variations in thickness or having regions of the support structure exposed, the wear upon the impact plate 106 may typically exhibit as denting or other plastic deformation and gradual, relatively even material loss across the entire surface of the impact plate 106, promoted by the impact plate 106 having a relatively constant structure across length and width.

[0033] This may be contrast against the prior art impact wear panel reinforcing element depicted in Figure 1 , comprising reinforcement blocks P- 12 welded to a support substrate mesh P-14, wherein continued impact from moving material on the multitude of exposed surfaces will either lead to significant chipping or shedding (direct impacts leading to large fragments being fractured off of the reinforcement block), or may ultimately dislodge entire reinforcement blocks P- 12 at once. This can lead to substantial contamination of the transported material, and also can necessitate that a particular prior art wear panel is retired sooner than expected.

The Impact Plate

[0034] In at least one embodiment, the impact plate 106 of the plate insert 104 is comprised of a sheet of material that may be single-layered or may comprise m ultiple layers bonded into a single sheet. As the skilled person may understand and without limiting the scope of the invention, it is envisaged that a single, solid sheet that is cut and/or otherwise shaped into the impact plate 106 is likely to be more resistant to fracturing or ‘shedding’ than prior art impact plates utilising wear blocks welded or otherwise bonded onto a support substrate. Such an embodiment may be particularly suited for high-velocity or high-force impacts, and may assist in ensuring that the impact plate wears away in small or minute fragments rather than as larger shed chips.

[0035] In an embodiment, the impact plate 106 may comprise at least one opening 108 extending vertically therethrough. It is considered that forming at least one opening 108 may enable the weight of the impact plate 106 to be reduced. It is further considered that, in a further embodiment wherein the impact wear panel 100 is constructed such that the panel body 102 is formed around the impact plate 106, the opening 108 may enable the material of the panel body 102 to penetrate through the impact plate 106 and more fully grip onto and encapsulate it. The opening 108 may be of any shape, size, configuration and number without departing from the scope of the invention. The opening 108 may enable for the provision of vertically-directed internal connections between an upper region of the panel body 102A and a lower region of the panel body 102B, and it is considered that this may inhibit, ameliorate or prevent shedding of the material of the panel body 102, particularly as the thickness of the panel body 102 decreases and an upper surface thereof approaches the impact plate 106, since the panel body material in the upper region 102A may still have some structural connection to the lower region 102B. The skilled person may appreciate that the inclusion of at least one opening 108 may particularly synergise with an embodiment wherein the panel body is elastomeric material such as vulcanised rubber, as the sulphur-induced intermolecular linkage characteristic thereof may enable improved panel body strength between the upper and lower regions 102A, 102B.

[0036] The shape of the opening 108 may vary depending upon the application of the impact panel 100. In some embodiments, the opening 108 may be circular or elliptical. I n other embodiments, the opening 108 may be extended in at least one direction. I n a further embodiment, the opening 108 may have the shape of a geometric stadium, or other shapes that are at least partially rounded. It is generally desirable to avoid right-angled corners (i.e. a square or rectangle) in an opening 108, as the corners may enable fracture propagation through the material of the impact plate 106.

[0037] In some embodiments wherein the opening 108 is extended in at least one direction, it may be advantageous to at least partially align the direction of extension with the direction of material flow. By way of non-limiting example, an opening 108 that is a geometric stadium in shape with its long axis at least partially aligned to the direction of material flow (hereafter referred to as the longitudinal direction) may promote or enable longitudinally-oriented connections to form between an upper region 102A and lower region 102B of the panel body 102. This may enable the material of the panel body 102 to more easily resist fracturing, shedding or other forms of breakage.

Improving Zone-Specific Surface Area

[0038] Without limiting the scope of the invention through theory, it is considered that in some situations and depending on particulate size and material movement speed, the direction of material flow will be substantially vertical or longitudinal, with limited relative lateral movement. As the skilled person may appreciate, in a scenario wherein an impact plate 106 comprises multiple openings 108 that are substantially longitudinally aligned with one another, then the impact plate 106 will have a substantially reduced surface area within this particular longitudinal region thereof. This may lead to a greater number of impacts to a lower region 102B of the panel body 102, increasing the rate of degradation and potentially reducing the lifespan of the material. This can also occur in situations wherein a particular opening 108 is longitudinally- extending in shape - however, an at least partial longitudinally-extending shape may be desirable for benefits laid out previously, and so a balance may need to be established.

[0039] Separately, edges that are perpendicular with respect to the direction of material movement (i.e. laterally-extending edges) are substantially more likely to be subject to direct impacts. With regard to an impact plate 106, as the material is moving substantially longitudinally or vertically, it may strike an edge of the impact plate 106 or an edge of an opening 108 on the perpendicular, leading to greater transmission of force directly into the plate 106. This can increase the likelihood of shedding, chipping or other forms of fragmentation of the impact plate 106, leading to potential contamination of the material.

[0040] In order to address the above scenario, in an embodiment, the impact plate 106 may be shaped to avoid creating a longitudinal region of the impact plate 106 having reduced coverage. I n one further embodiment and with reference to Figure 3, this may comprise arranging openings 108 in order to stagger or offset their lateral positions from one another, such that no longitudinal region of the impact plate comprises an inordinate number of openings 108. I n another embodiment and with reference to Figure 4, the openings 108 may be shaped to minimise any opening edges 108A that are perpendicular to a direction of material flow. I n an embodiment wherein the openings 108 extend in at least one direction, the direction of extension may be determined as a balance between avoiding opening edges 108A being perpendicular to the longitudinal, and avoiding the direction of extension being parallel thereto (and thereby reducing coverage of the respective ‘zone’ by the impact plate 106) . The skilled person will appreciate that these embodiments are not mutually exclusive from one another, and that both angled extension and staggering may be combined in a single plate. [0041 ] In an embodiment and with reference to Figure 5, the impact plate may be shaped to comprise opening 108 having a wave-like, oscillating or substantially sinusoidal shape, wherein each oscillation or wave extends perpendicular to the direction of material flow, and the opening extends overall in a direction substantially aligned to the direction of material flow. The oscillating shape to opening 108 may promote improved longitudinally-oriented connectivity between upper region 102A and lower region 102B of the panel body 102, while also substantially lim iting exposure of opening edge 108A to direct, substantially perpendicular impacts. It is also considered that the substantially sinusoidal shape ensures that no longitudinal region of the impact plate 106 suffers from reduced surface area or coverage, and so the lower region 102B (not shown in Figure 5) is not overly exposed in one area.

Provision of a Stand

[0042] In an embodiment, the plate insert 104 may further comprise at least one stand 1 10 extending from an underside of the impact plate 106. The stand 1 10 may enable the plate insert 104 to be positioned such that, upon being encapsulated by the impact wear panel body 102, the impact plate 106 is at a particular height, with the intention that the stand form part of the structure of the plate insert. It is considered that by varying a length of the stand 1 10, the lifespan of the impact wear panel 100 may be altered by altering the length of time until the upper surface of the plate insert 104 is exposed. I n some embodiments, once the impact plate 106 of the plate insert 104 (or the wear layer 106A, in such an embodiment) is substantially worn away, the impact wear panel 100 may be considered ‘spent’, having reached the end of its usable lifespan. Therefore, by adjusting a vertical position of the impact plate 106 within the panel 100 during construction (and thus adjusting a thickness of the upper portion of the panel body 102A) , one can increase or decrease the lifespan of the impact wear panel 100 accordingly.

[0043] In an embodiment and as shown in Figure 2, the stand 1 10 may comprise a vertical element 1 10A. The stand may or may not comprise a base element 1 10B. The vertical element 1 10A may be formed as part of the underside of the impact plate 106. I n alternative embodiments, the vertical element 1 10A may be constructed separately and attached to an underside of the impact plate 106, for example through welding. I n some embodiments, the vertical element 1 10A may be a plate element, having a length much greater than a width. I n one embodiment, the vertical element 1 10A may be oriented such that its length is parallel to a direction of material flow across the impact panel 100. In an alternative embodiment, the vertical element 1 10A may be oriented such that its length is perpendicular to a direction of material flow across the impact panel 100. Further alternatively, the vertical element 1 10A may be oriented at any angle therebetween.

Impact Plate Construction

[0044] In an embodiment, the impact plate 106 may be comprised of one or more of a ceramic, metal, metal alloy and combinations thereof. I n at least the present embodiment, the impact plate 106 may be formed of a material configured to possess a high value for at least one of impact toughness, abrasive resistance, yield strength and Brinell hardness.

[0045] In at least one embodiment wherein the impact plate 106 is at least partially comprised of a ceramic, the ceramic may be a carbide. I n a further embodiment, the carbide may be any of tungsten carbide, titanium carbide, tantalum carbide, chromium carbide, molybdenum carbide, niobium carbide, vanadium carbide, hafnium carbide and zirconium carbide, or a mixture thereof. In an embodiment, the carbide may be micro-alloyed with one or more of molybdenum, niobium, nickel, vanadium , tungsten, titanium , cobalt and iron. I n a further embodiment, the carbide may be combined with a metal or metal alloy in a sintering process. I n an alternate embodiment, carbide crystals may be integrated into a surface of a metal or metal alloy. I n a further alternate embodiment, the carbide may be deposited onto a surface of a metal or metal alloy through a welding process, wherein the metal or metal alloy may be at least partially melted. I n such an embodiment, a further additive may be used to induce and promote fusion of the carbide and metal or metal alloy. I n an alternate embodiment, the carbide may be deposited onto a metal or metal alloy surface through a thermal spray coating process, for example a high-velocity oxygen fuel (HVOF) spray deposition process. [0046] In an embodiment wherein the impact plate 106 is at least partially comprised of a metal alloy, the metal alloy may be a metal, or m ixture of metals, m icro-alloyed with one or more of molybdenum , niobium, nickel, vanadium , tungsten, titanium, cobalt, zirconium, boron, rare-earth metals and carbides, wherein the carbides are one or more of the carbides laid out previously. I n an embodiment wherein the impact plate 106 is at least partially comprised of metal or a metal alloy, the metal or metal alloy may be carburised in order to form a carbide coating on at least one surface thereof. In a further embodiment, the carbide coating may be formed from one or more of the carbides laid out previously.

[0047] In an embodiment and with reference to Figure 6, the impact plate 106 may have an upper wear layer 106A and a lower support layer 106B. I n an embodiment, the wear layer 106A may be formed from a wear material selected for high toughness and impact resistance, with the support layer 106B being formed from a substrate material selected from suitable substrates that are compatible with the wear material of the wear layer and with the panel body. I n an embodiment, the wear layer 106A may be one or more of a ceramic, metal or metal alloy as laid out previously. In an embodiment, the support layer 106B may be metal or metal alloy. I n a further embodiment, the support layer 106B may be at least partially comprised of iron or steel.

[0048] Without wishing to lim it the scope of the invention through theory, it is envisaged that providing a dual-layered structure for the impact plate 106 may enhance its functionality, particularly in situations wherein the impact panel 100 is to be subject to high velocity material, material of increased hardness, or situations where panel wear rate may otherwise be exacerbated. The wear layer 106A which is an upper layer of the impact plate 106 is the layer that is directly subject to impacts once the panel body 102 has sufficiently worn away, and therefore, is ideally comprised of a material suited to resisting impact without undergoing substantial shedding. However, some materials that are highly resistant to impact are somewhat brittle, and so are less resistant to fracture under shear stress. In such an embodiment, the support layer 106B may provide a measure of rigidity, structure and flexibility to the wear layer 106A, and may prevent, inhibit or ameliorate the wear layer 106A fracturing under shear stress. The skilled person may appreciate that constructing the impact plate 106 as a multi-layered sheet provides both flexibility for resistance to fracture and significant toughness for resistance to impact, without sacrificing resistance to chipping or shedding.

[0049] In an embodiment and with reference to Figure 7, the impact plate 106 may further comprise a wear indicator 1 12 that is configured to indicate that the wear layer is substantially worn and is approaching the end of its lifespan. The wear indicator 1 12 may be further configured to be highly visible such that, during equipment inspection, a user may readily identify that an impact wear panel 100 of an embodiment of the present invention is substantially worn, may be approaching the end of its lifespan, and requires replacement. In a further embodiment, the wear layer 106A may comprise an aperture 1 14 extending therethrough and terminating approximately at the support layer 106B. I n such an embodiment, the wear indicator 1 12 may be positioned within the aperture. In a further embodiment, the aperture 1 14 may be filled following positioning the wear indicator 1 12 therein, such that the wear indicator is hidden until the material filling the aperture 1 14 is worn away. In an alternate further embodiment, the wear indicator 1 12 may be shaped to be at least partially hidden or otherwise less visible to a user conducting an inspection until the material of the wear layer 106A is sufficiently worn away.

[0050] In a further embodiment and with reference to Figure 8, the impact plate 106 may comprise varying different materials and/or different thicknesses across its length. As the skilled person will appreciate and with reference to Figure 9, different areas of an impact wear panel 100 may suffer wear at different rates. By way of non-limiting example, Figure 9 depicts a simple diagram of an example ore chute 106 that deposits ore, rock and grounds onto a set of impact wear panels 106C, 106D. As the skilled person will appreciate, a greater flow rate of ore will be deposited onto the impact wear panels 106C, 106D through Zone 1 when compared to Zone 2, and Zone 2 will have a greater ore flow rate when compared to Zone 3. As a result, in at least some embodiments, an impact wear panel 100 that straddles (for example) Zones 1 & 2 would incur a greater rate of wear in the area thereof positioned in Zone 1 when compared to the area positioned in Zone 2. Therefore, in order to ensure that different areas of an impact wear panel have an approximately similar lifespan, it may be necessary to provide a varied thickness across a dimension of the impact plate. Alternatively (or additionally), the material composition of the impact plate 106 (or wear layer 106A) .may be varied across a dimension thereof. In a further embodiment wherein the impact plate 106 comprises an wear layer 106A and support layer 106B, the wear layer 106A may have a varied thickness across its length and/or width. The support layer 106B may vary in thickness to improve support structure or may be essentially constant.

Multiple Impact Plates

[0051 ] In an embodiment, the impact wear panel 100 may comprise a plurality of impact plates 106C, 106D. I n one further embodiment and with reference to Figure 10, the impact plates 106C & 106D are provided as separate plate inserts 104C, 104D, within the panel body 102, and having separate stands 1 10C, 1 10 D. Alternatively and with reference to Figure 1 1 , the impact wear panel may comprise a single plate insert 104 with multiple impact plates 106C, 106D and a shared impact plate stand 1 10. The skilled person will appreciate that any number of impact plates be utilised without departing from the object of the invention, provided that the impact plates 106C, 106D are still ‘plates’. I n a further embodiment and with continued reference to Figure 1 1 , the plurality of impact plates 106C, 106D may have a substantially wave-like, oscillating, or sinusoidal shape. This may provide similar benefits to previous embodiments comprising a single plate 106 with oscillating, sinusoidal or wave-shaped openings 108.

[0052] In a further embodiment, the plurality of impact plates 106C, 106D may comprise different materials and/or different thicknesses. With reference to Figure 9, impact plates 106C, 106D of different thickness may provide a similar benefit to that of a single impact plate 106 having a varying thickness across a dimension thereof. In a further embodiment (not shown) , a single impact plate 106C within the plurality of impact plates may have a varying composition and/or thickness across a dimension thereof. [0053] In an embodiment and with reference to Figure 12, the plate insert may comprise a plurality of impact plates 106C, 106D that are stacked vertically, or depth wise, within the impact wear panel 100. Such an embodiment may enable the lifespan of the impact wear panel 100 to be substantially altered.

[0054] The skilled person will appreciate that the above embodiments of the present invention comprising multiple impact plates 106C, 106D are not mutually exclusive from one another, and may be freely combined with each other and with other embodiments disclosed above without departing from the scope of the present invention. For example, the plurality of impact plates 106C, 106D may each comprise one or more openings 108, an aperture 1 14 with a wear indicator 1 12, or any other variation disclosed herein.

[0055] As the skilled person may appreciate, the impact wear panel 100 may be formed in any shape or configuration as required by the intended application thereof. By way of non-lim iting example, the impact wear panel 100 may be formed into a bar-shaped panel. I n a further non-limiting example, the impact wear panel 100 may have an intended application as a screening impact wear panel comprising at least one screen opening extending therethrough. In such an embodiment, at least one opening 108 of the impact plate 106 may be arranged to substantially align with the at least one screen opening of the screening impact wear panel 100, such that material of a particular size or smaller may pass through the screening impact wear panel 100. I n a further alternate embodiment, the impact wear panel 100 may be formed as an impact mesh panel. I n such an embodiment, and as the skilled person may appreciate, the impact plate 106 may comprise a plurality of openings 108 substantially aligned with the mesh openings in the impact mesh panel 100.

[0056] In a further alternate embodiment, the impact wear panel 100 may be curved along at least one axis. In such an embodiment, the impact plate 106 may also be curved along a substantially similar axis.

[0057] In a second aspect, the present invention may comprise a method of constructing an impact wear panel 100 for use in a material transport, com minution or processing train, the impact wear panel 100 comprising an elastomeric impact wear panel body 102 and a plate insert 104 comprising an impact plate 106 having at least one opening 108 vertically extending therethrough. I n an embodiment, the method comprises the steps of:

(1 ) forming the impact plate 106 by cutting a sheet of wear material, and cutting the at least one opening 108,

(2) positioning the impact plate 106 within a mould of the impact wear panel body 102 at a predeterm ined depth, and

(3) injecting, pouring, casting or otherwise forming the impact wear panel body 102 within the mould, such that the impact wear panel body 102 encapsulates the impact plate 106 and extends through the at least one opening, wherein the predetermined depth is determined as a function of a target lifespan of the impact wear panel 100 and at least one operating condition of the impact wear panel 100.

[0058] In an embodiment of the present invention, the operating condition may include at least one condition that affects the rate at which the material of the impact wear panel body 102 wears away when installed at an installation site of the impact wear panel 100 in the ore processing train. By way of non limiting example, the operating condition may be one or more of an initial and/or current thickness of the impact wear panel 100, an initial and/or current thickness of the impact plate 106, an average volumetric and/or mass flow rate of material at the installation site, an average density of material at the installation site, an average hardness of material at the installation site, an average size and/or size range of material at the installation size and an average impact force exerted by material at the installation site. These and other operating conditions may assist in determining a wear rate of a material of the impact wear panel body 102 or impact plate 106, which may enable an impact wear panel 100 to be sized in order to achieve a target lifespan.

[0059] In an embodiment of the present invention, the thickness of the impact wear panel 100 may be a thickness of an upper region 102A of the panel body 102. I n an embodiment of the present invention wherein the impact plate comprises an wear layer 106A and support layer 106B, the thickness of the impact plate 106 may be the thickness of the wear layer 106A. [0060] In a further embodiment of the present invention, the step of positioning the impact plate 106 within a mould of the impact wear panel body 102 at a predetermined depth may comprise the steps of:

(1 ) attaching at least one panel stand 1 10 having a length corresponding to the predetermined depth to an underside of the impact plate 106, and

(2) positioning the plate insert 104 within the mould, such that the panel stand 1 10 supports the impact plate 106 of the plate insert 104 at the predetermined depth.

[0061 ] In an alternative embodiment, the step of positioning the impact plate 106 within a mould of the impact wear panel body 102 at a predetermined depth may comprise the steps of:

(1 ) filling the mould with elastomeric material to form a lower region 102B of the panel body 102, the lower region having a thickness matching the predetermined depth, and

(2) positioning the plate insert 104 within the mould, on top of the lower region 102B.

[0062] It may be advantageous to carry out this alternative be method while the material of the lower region 102B is still molten, so that when the mould is filled with elastomeric material to form the upper region 102A, inter-regional or vertical connections and/or bonds are encouraged to form therebetween.

[0063] While the invention has been described with reference to preferred embodiments above, it will be appreciated by those skilled in the art that it is not limited to those embodiments, but may be embodied in many other forms, variations and modifications other than those specifically described. The invention includes all such variation and modifications. The invention also includes all of the steps, features, components and/or devices referred to or indicated in the specification, individually or collectively and any and all combinations or any two or more of the steps or features.

[0064] Embodiments of the impact wear panel disclosed herein may be implemented within an ore processing train in any useful configuration, orientation or alignment. Unless otherwise specified, directional terms such as horizontal and vertical are used to define the orientation of components of an embodiment of the impact wear panel with respect to one another, and are not intended to limit the impact wear panel to being used only in a flat, horizontal configuration within an ore processing train.

[0065] While the invention has been described with reference to preferred embodiments above, it will be appreciated by those skilled in the art that it is not limited to those embodiments, but may be embodied in many other forms, variations and modifications other than those specifically described. The invention includes all such variation and modifications. The invention also includes all of the steps, features, components and/or devices referred to or indicated in the specification, individually or collectively and any and all combinations or any two or more of the steps or features.

[0066] In this specification, unless the context clearly indicates otherwise, the word "comprising” is not intended to have the exclusive meaning of the word such as “consisting only of”, but rather has the non-exclusive meaning, in the sense of “including at least”. The same applies, with corresponding grammatical changes, to other forms of the word such as “comprise”, etc.

[0067] Other definitions for selected terms used herein may be found within the detailed description of the invention and apply throughout. Unless otherwise defined, all other scientific and technical terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which the invention belongs.

[0068] Any promises made in the present document should be understood to relate to some embodiments of the invention, and are not intended to be promises made about the invention in all embodiments. Where there are promises that are deemed to apply to all embodiments of the invention, the applicant/patentee reserves the right to later delete them from the description and they do not rely on these promises for the acceptance or subsequent grant of a patent in any country.