Field of the invention

[001] The present invention relates to wear liners for crushing and mining equipment, transfer chutes and similar apparatus or equipment. More particularly it relates to ceramic wear liners on a steel base plate.

Background of the invention

[002] Conveyor systems, chutes, and the like, are used in the mining and ore processing industries to transport or process raw materials such as minerals and ores. In the course of such transport, the interior surfaces of the transport or conveyor systems or chutes would otherwise be in physical contact with the raw materials, and thus the apparatus surfaces would be subject to wear caused by physical abrasion.

[003] To protect the inner surfaces of an apparatus against wear, wear liners are provided on the surfaces. The liners are made of a hard wearing material, such as ceramic. The liner can be made of a number of ceramic tiles, so that when a liner becomes damaged, it can be replaced. The replacement of a wear liner, rather than a replacement or repair section of the chute or the conveyor system, reduces the downtime involved.

[004] As the apparatus and or chutes are usually constructed from metal plate which can be joined together, the wear liners may be required to extend over uneven surfaces where the metal sheets are joined. Such wear liners are generally located on liner plates having welded studs or bolts, which pass through an apparatus wall, and are secured by nuts and washers which are torqued in place by rattle guns or other powered means. Such rattle guns thus cause the liner plates to bend thereby compromising the integrity of the bonding matrix which bonds the ceramic material to the liner plate.

[005] Any reference herein to known prior art does not, unless the contrary indication appears, constitute an admission that such prior art is commonly known by those skilled in the art to which the invention relates, at the priority date of this application.

Summary of the invention

[006] The present invention provides a backing plate for a liner for lining a surface of a materials handling or transporting equipment, the backing plate comprising a first side and a second side; the first side being adapted to have attached to it a layer of hardwearing material, the backing plate having one or more attachment means on its second side adapted to enable attachment of the backing plate to the surface; the backing plate including a deformation formation associated with the or each attachment means, whereby the or each deformation formation is adapted to be displaced from the backing plate when assembly of the liner overlays a localised unevenness or discontinuity on the surface.

[007] The deformation formation can formed by an incision or cut through the backing plate.

[008] The incision or cut can be formed any known means including laser, water jet, plasma cutter, laser, electro discharge machine, or mechanical processes such as punching.

[009] The or each deformation formation can be a tab.

[010] The deformation formation can include a blind or through aperture to receive each associated attachment means.

[011] The deformation formation can have a base or portion at which the deformation formation is connected to the backing plate, and a movable part adapted to be movable about the base.

[012] The movable part can have an end edge which is curved, straight, or angular.

[013] The deformation formation can include: a free edge which is curved or rounded.

[014] The deformation formation can include a movable part having straight edges which extend from a free edge.

[015] The straight edges can be one of the following: non-parallel to each other; parallel to each other.

[016] A backing plate can have multiple attachment means and corresponding deformation formations which are generally evenly spaced apart from each other.

[017] The backing plate can be made from one or more of the following: steel, composite material, metal, polymeric material.

[018] The backing plate can include a deformation formation which is preformed into the backing plate to provide a clearance between the base of the deformation formation and the backing plate. [019] The present invention also provides a wear liner for lining a surface of a materials handling or transporting equipment, comprising a backing plate as described above and below, the backing plate can have attached to it a layer of hardwearing material.

[020] The layer of hardwearing material can be adhered or bonded to the backing plate.

[021] The layer of hardwearing material can be co-extensive with the backing plate.

[022] The layer of hardwearing material can comprise a plurality of panels or tiles of the hardwearing material which are bonded together.

[023] The hardwearing material can be one of: a composite material, a ceramic material, an abradable material.

[024] The present invention also provides an equipment for transporting or handling materials, comprising of panels or components that are to be protected, the equipment having an surface of the panels or components which is lined with one or more wear liners as described above.

[025] The present invention also provides a method of making a liner for a materials handling or transporting apparatus, comprising making cuts or incisions into a backing plate so as to relieve a portion of the backing plate so that it is able to deform relative to the rest of the backing plate, providing attachment means for attaching the liner to the equipment on the portion; bonding to the backing plate a layer of hardwearing material.

[026] The present invention further provides a method of making a liner for a materials handling or transporting apparatus, comprising providing attachment means for attaching the liner to the equipment to a backing plate; making cuts or incisions into a backing plate around the attachment means so as to relieve a portion of the backing plate so that it is able to deform relative to the rest of the backing plate, bonding to the backing plate a layer of hardwearing material.

Brief description of the drawings

[027] An embodiment or embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[028] Figure 1 is a front perspective view of two wear liners, each of six ceramic wear elements, bonded or adhered to a liner backing plate for mounting to a part of an apparatus to be protected such as a chute wall;

[029] Figure 2 is a rear perspective view of the wear of the wear liners of figure 1 ; [030] Figure 3 is a cross section of wear liners of figures 1 and 2;

[031] Figure 4 is a cut away rear perspective view of the chute wall of previous figures showing welded studs and deformable tabs;

[032] Figure 5 is a side view depicting the backing plate or liner plate of the previous figures with ceramic tiles and bonding material removed showing a deformable tab in a deformed condition;

[033] Figure 6 is an underneath perspective view of the backing plate or liner plate of figure 5;

[034] Figure 7 is an underneath perspective view another backing plate or liner plate with deformable tabs of different shape to the previous embodiments, one of which is shown in a deformed condition;

[035] Figure 8 is an underneath perspective view yet another liner plate or backing plate with deformable tabs of different shape to the previous embodiments, one of which is shown in a deformed condition;

[036] Figure 9 is an underneath perspective view yet another liner plate or backing plate with deformable tabs of different shape to the previous embodiments, one of which is shown in a deformed condition;

[037] Figure 10 is a plan view of the liner plate or backing plate of figures 1 to 5 depicting the deformable tabs before stud bolts are installed, one of which is shown in a deformed condition;

[038] Figure 10A is a side view of the liner plate or backing plate of figure 10;

[039] Figure 11 is a perspective view of the backing plate and deformable tabs shown in

Figure 10;

[040] Figure 12 illustrates an underneath perspective view of another backing or liner plate embodiment, where the deformation formation is a riveted attachment and one of which is shown in a deformed condition;

[041] Figure 13 illustrates a side view of the backing or liner plate of figure 12;

[042] Figure 14 illustrates a plan view of the unassembled backing or liner plate of figure 12 with the tabs not yet installed by rivet into the holes; [043] Figure 15 illustrates a plan view of the deformation member or stud mount prior to attachment to the liner plate;

[044] Figure 16 illustrates an underneath perspective view of another embodiment where the deformation formation is a welded attachment, one of which is shown in a deformed condition;

[045] Figure 17 illustrates a side view of the liner plate of figure 16;

[046] Figure 18 illustrates a plan view of the liner plate of figure 16;

[047] Figure 19 illustrates a plan view of the deformation member stud mount prior to attachment to the liner plate;

[048] Figure 20 illustrates an underneath perspective view of a another embodiment, wherein a deformation formation is pre-formed in the liner plate;

[049] Figure 21 illustrates a side view of the liner plate of figures 20; and

[050] Figure 22 illustrates a wear liner formed from the liner plate of figures 20 and 21.

Detailed description of the embodiment or embodiments

[051] Shown in Figures 1 to 4, are two wear liners 10 mounted to a surface 1 that requires protective covering, being an interior surface of a processing apparatus such as a transport chute of mining or mineral ore processing equipment. However the surface 1 can be a surface of any other equipment or apparatus needing a wear liner to protect it. For the following, the mounting surface 1 is taken to belong to a mineral or ore transport chute, however this will be understood to not be a limiting feature of the invention.

[052] As shown in Figures 1 to 4, the surface 1 of the equipment to be protected can be constructed from plate steel panels 4.1 and 4.2 or similar components. The plate steel panels 4.1 and 4.2 are joined together by welded joints 4, which will sit proud of the surface as is illustrated in the figures, as these are the cheapest welds to make. Such welded joints 4 will result in a localised unevenness of the final surface 1 to be protected by the liners 10. The local unevenness might otherwise be caused by adjacent sheets being overlaid rather than butt joined, or it could be the result of joining plates and bolt heads each of which sit proud of the surface to be protected, or it could be from patch repairs on a chute or apparatus where the wall has blown out.

[053] As shown in Figure 3, each wear liner 10 includes a liner plate, base or backing plate 7. The backing plate 7 will be a plate to which can be bonded or adhered ceramic wear members 2 as will be described later. The backing plate 7 is preferably made from a material such as steel or similar.

[054] A first side 7.1 of the backing plate 7 is attached to the mounting surface 1 by attachment means 3. The attachment means may be screws, bolts or studs 3 which are preferably welded in place, but may be bolted or screwed, onto the backing plate 7. The attachment means 3 will pass through holes in the surface 1, and can be secured thereto by means of nuts 5 and washers 11 to the surface 1 to be protected. As better shown in Figure 4, each attachment means 3 has associated with it a deformable formation or tab 9, 9', which will be described in more detail below. The backing plate 7 when initially formed, preferably has all tabs 9 and 9' flush with the backing plate 7 upper and lower surfaces, that is, no initial deformation is present.

[055] The opposite, second side 7.2 of the backing plate 7 has attached to it a layer of hardwearing material 15, in this case made up of a plurality ceramic area members 2. The hardwearing material can be any appropriate material such as ceramic. The hardwearing layer 15 makes contact with the transported material, thereby protecting the underlying surface 1 and the base or backing plate 7. The layer of hardwearing material 15 can be bonded to the backing plate 7 by a layer or matrix of bonding material or adhesive 8. The hardwearing layer 15 can include a single, unitary piece of the hardwearing material 2 which is co-extensive with the support number 7, or it can be made from a plurality of pieces which in the case of figure 1 is 18 pieces or tiles. However, the wear liner 10 can have any appropriate number of hardwearing material pieces to comprise the hard wearing material 15.

[056] As further shown in Figure 1 to 4, the wear liners 10 are overlaid on the surface 1 that contains a weld line 4 or other local unevenness 4. The local unevenness 4 can be accommodated by the deformable formations 9, 9' . The deformable formations 9, 9' when activated, allow the backing plate 7 to remain generally planar, so that the bonding matrix or system of the hardwearing surface is not compromised, or so that any compromising is minimised. This can assist to extend the life of the bonding matrix by not putting the resin or adhesive under undue stress.

[057] As shown in Figure 4, the deformable formations 9, 9' are in the form of tabs. The tabs are formed by a cut 25, such as a laser cut, through the thickness of the backing plate 7. A base 20 of the tab or deformable formation 9, 9' remains uncut and thus connected to the backing plate 7. The base 20 is drawn as a line, which will only technically form, when a tab 9 is bent from the plate 7. The remaining part of the tab or deformable formation 9, 9' is a movable part 30 which can be rotated or bent away from the rest of the backing plate 7, and movable about the base 20 or more particularly about an axis located in the plane of the base 20. The cut 25 therefore forms an end edge of the tab, which is movable with respect to the backing plate 7. Figure 4 further shows that each tab or deformable formation 9, 9' is provided such that the attachment means 3 extends through the tab or deformable formation 9, 9' . A through aperture 35 can be cut through the backing plate 7 to accommodate and or receive the attachment means 3 which is preferably a threaded stud.

[058] The above embodiment preferably has the incision or cut portions 25 first made in the base or backing plate 7 and then the attachment means 3 attached. If desired the attachment means 3 can be first directly bolted or welded to or through the backing plate 7, and then the incision or cut 25 is made, to form the formations which make up the respective tabs 9, 9'. In both instances the preferred thickness of the liner plate or backing plate 7 is 6mm, while the width of the incision or cut 25 is of the order of 0.2 to 0.25mm in thickness. The cut or incision can be made by any known means such as water jet, plasma cutter, laser, electro discharge machine, or mechanical processes such as punching etc.

[059] The thickness of the cut or incision does to some extent depend upon the type of deformation which will occur. Thus for greater liner plate or backing plate thicknesses, the width of the incision or cut may need to increase. This may be the case if the stud mount or deformation formation may be expected to rotate relative to the liner plate or backing plate. An incision or cut which is wider will assist in preventing jamming of the moving/rotating deformation member 9, 9' against the liner plate or backing plate.

[060] As further shown in Figures 1 to 6, the wear liner 10 overlies a local unevenness

4. As a result, the one or more of the tabs or deformable formations, in this case the tab 9', is flexed away or elastically or plastically displaced, moved or rotated and or deformed from the underneath or base plane of the backing plate 7. The attachment means 3 that is associated with the moved tab 9' is therefore also angularly displaced. This mechanism will prevent the backing plate 7 bending which will otherwise adversely affect the integrity of the bonding matrix of the liner 10. The movement of the tab 9' from the backing plate 7 can be also seen in Figures 10 and 11.

[061] In the embodiment shown in Figure 6, the deformation formations 9, 9' are tabs which include curved end edges 25.1. In this embodiment, the wear liner 10 includes four attachment means 3, and therefore four associated deformation formations 9, 9', in the form of generally cuneiform or generally triangular tabs. The deformation formations are preferably evenly spaced about a centre of the backing plate 7, but can be provided in any arrangement as needed by the design criteria so as to match pre-existing apparatus or equipment mounting holes. The bases 20 of the tabs or deformation formations 9, 9' are straight edges which face toward the interior portion of the flexible backing plate 7. The movable edges 25 are generally oriented toward the four corners of the backing plate 7. The edges 25 include an arcuate or curved centre free edge 25.1, flanked by two generally straight edges 25.2, 25.3, which each extend from the base 20 to the centre free edge 25.1. The straight edges are at an angle, i.e. non-parallel, to each other. The resulting tab or deformation formation 9, 9' assumes a generally triangular shape but has a curved or rounded corner.

[062] Figures 7 to 9 depict other examples of tabs or deformation formations 9, 9' which can be provided. Differently shaped tabs or deformation formations 9, 9' can be provided to suit a particular deformation stress. In the embodiment shown in Figure 7, the two straight edges 25.2, 25.3 are parallel to each other. The straight edges 25.2, 25.3 lead to an arcuate centre edge 25.1, which covers more than 180 degrees of a circle or arc. The attachment means 3 is provided through the centre of the tab's end circular or arcuate formation. The resulting tab 9, 9' is shaped like a key hole.

[063] In Figure 8, the cut 25 is generally U-shaped, with a base 20 that is oriented toward the centre of the of the backing plate 7. The side edges 25.2, 25.3 are generally straight and parallel to each other, connected by a centre edge 25.1 that is curved.

[064] In Figure 9, the cut 25 is also generally U shaped, however the centre edge 25.1 is mostly straight. The two side edges 25.2, 25.3 are straight and parallel to each other. The corners between the centre edge 25.1 and the side edges 25.2, 25.3 are rounded.

[065] As shown in Figures 1 to 6, the wear liner 10, though affected by overlying the local unevenness 4, accommodates it by allowing the base or backing plate 7 to be secured without adverse bending which would otherwise compromise the bonding matrix. As a result, a better hardwearing liner assembly is produced than available in the prior art.

[066] Illustrated in figures 12 to 15 is another embodiment of a backing plate 7 for a wear liner, whereby the deformation formation is formed by first making a shaped cut out 43 as in figure 14 in the backing plate 7. Then a separate deformation member or tab 41 is made being of a complementary shape to the cut out 43. The tab 41 can be made of a different material to that of the backing plate. The tab 41 includes two holes 42 so that the ends of the tab 41 can be secured by a rivet or fastener 40 to the base plate 7 through the holes 45 in the base plate 7 and holes 42 in the tab 41 as best illustrated in figures 13 to 15. While the illustrated embodiment of figures 12 to 15 shows riveting or fasteners being used to attach the ends of tab 43 to the base plate 7, it will be understood that any joining or connection means could be utilised such as welding etc.

[067] The shape of the tab 41, being of a boomerang or "L" shape, and the cut out 43 is such that the rivets 40 will keep the tab ends 41.1 in contact with the base plate 7, while the nut (not illustrated here but is item 11 in Figure 1) is torqued up, usually to the maximum, to secure the wear liner 10 to an apparatus. The legs of the tab 41 will bend and deform when the stud 3 inserted in to central portion 41.2 is secured to a surface 1 of an apparatus to be protected. As in other embodiments described above the tab member 41 will deform during securement such the material of the central portion 41.2 around the welded stud 3, will end up resting against the apparatus surface 1, and this will prevent the backing plate 7 bending which would otherwise cause the bonding matrix to deteriorate.

[068] It can be seen from figure 13, that the rivet 40 and tab 41 are located on the upper surface of the backing plate 7. Accordingly, a layer of bonding material or adhesive can be provided at a sufficient thickness so that the rivet 40 and tab 41 do not result in a tile protruding from the exposed upper surface of the hardwearing liner.

[069] By the tab 41 being separate it can be manufactured from steel or other material which is different from the base plate 7. By being different, a different material property can be selected for the deformation formation or tab 41 to better suit the environment into which the wear liner will be inserted. In the embodiment of figure 12 to 15, as the tab 41 is relatively thin, it can be manufactured from steel having greater strength or elastic modulus that the material of the base plate 7.

[070] Illustrated in figures 16 to 19 is another embodiment which is similar to that of figures 12 to 15, except that the tab 51 is welded to the base plate 7, at the weld beads 50. The advantage of this embodiment over that of figures 12 to 15 is that, as is best seen in figure 17, no part of the tab 51 is sitting proud of or past the surfaces 7.1 or 7.2 of the backing plate 7, whereas, depending upon the weld, there may be some weld bead proud of the surface 7.1 of the plate 7, but this should not cause issues during assembly.

[071] In the embodiments of both figures 12 to 15 and 16 to 19, the tabs 41 and 51 can be first drilled (either a through bore or a blind bore) and then a stud 3 welded in place before the tab 41, 51 is secured to the base plate 7, or if desired the drilling the hole and welding of a stud 3 can be done after attachment of the tab to the base plate 7.

[072] Illustrated in figures 20 to 22 is another embodiment wherein the base plate 7 has a deformation formation 60 which is pre-formed or pre-displaced in the base plate 7, by pressing or other method. The depth 61 of the deformation formation 60, can be produced to suit a particular project by a user, or alternatively, a depth of 4 mm to 6 mm should be able to cope with the majority of local unevenness 4 encountered by the wear liner when assembled to an apparatus. The deformation formation 60 provides a clearance between the base 62 of the deformation formation and the surface 7.1 of backing plate 7.

[073] The thicknesses of the backing plates and the thicknesses of the hardwearing material are selected according to the application and hardwearing material life and many other factors as deemed appropriate with regards to lining applications. The spacing between the hardwearing materials and the corresponding thickness and or type of adhesive or bonding material are also selected according to need.

[074] While the above description details that the backing plate 7 is made from steel, any appropriate materials such as other metals, composites or polynomic materials can be used.

[075] The above described embodiments, in particular, that of figures 1 to 4 provides a relatively inexpensive solution to the uneven surface problem. The embodiment of figures 1 to 4 is able to be used to cover the whole surface to be protected with the function of the deformation formations kicking in where needed. Alternatively, users can purchase prior art wear liners, and where local unevenness exists, purchase an embodiment as described above.

[076] While the embodiments of Figures 1 to 19 are manufactured such that each of the tabs 9, 9', 41, 51 are such as to be not proud of the surface 7.1 at the time of manufacture, it will be readily understood that a predetermined amount of displacement past surface 7.1 could be provided in the tabs 9, 9', 41, 51 if it suits the application or environment.

[077] It will be understood by a person of ordinary skill in the art that a plurality of the above described wear liners can be assembled together to line a larger mounting surface of the underlying equipment.

[078] Where ever it is used, the word "comprising" is to be understood in its "open" sense, that is, in the sense of "including", and thus not limited to its "closed" sense, that is the sense of "consisting only of. A corresponding meaning is to be attributed to the corresponding words "comprise", "comprised" and "comprises" where they appear.

[079] It will be understood that the invention disclosed and defined herein extends to all alternative combinations of two or more of the individual features mentioned or evident from the text. All of these different combinations constitute various alternative aspects of the invention. [080] While particular embodiments of this invention have been described, it will be evident to those skilled in the art that the present invention may be embodied in other specific forms without departing from the essential characteristics thereof. The present embodiments and examples are therefore to be considered in all respects as illustrative and not restrictive, and all modifications which would be obvious to those skilled in the art are therefore intended to be embraced therein.