A Replaceable Wear Liner with Super Hard Composite Inserts
In one aspect of the invention, a rock crusher has a crushing chamber disposed between two opposing walls and at least one of the walls comprising a replaceable wear liner. The replaceable wear liner has a plurality of super hard composite inserts disposed within a plurality of cavities formed in a crushing surface of the replaceable wear liner. The super hard composite inserts have a layer of diamond or cubic boron nitride.
1 . A replaceable wear liner for incorporation in a cone crusher comprising;
a crushing surface with a plurality of super hard composite inserts disposed within cavities in the crushing surface,
at least one of the plurality of super hard composite inserts extending from said crushing surface and comprising a carbide substrate forming the base segment bonded at a non-planar interface to either a sintered polycrystalline diamond or a sintered polycrystalline cubic boron nitride material which forms a wear resistant tip.
2 . The replaceable wear liner of claim 1 , wherein the replaceable wear liner comprises a base segment of manganese, steel, stainless steel, or combinations thereof.
3 . The replaceable wear liner of claim 1 , wherein the replaceable wear liner comprises a second layer of cemented metal carbide base segment comprised of a material selected from the group consisting of tungsten carbide, niobium carbide, and manganese carbide at a thickness of between 0.100 to 0.200 inches.
4 . The replaceable wear liner of claim 1 , wherein the crushing surface comprises a complementary geometry that corresponds with either a conical head or concave bowl.
5 . The replaceable wear liner of claim 1 , wherein the cavities are disposed around a peripheral circumference of the replaceable wear liner and form concentric circular rows around the replaceable wear liner.
6 . The replaceable wear liner of claim 1 , wherein the super hard composite inserts comprises a base segment comprising a material selected from the group consisting of manganese, steel, stainless steel, cemented metal carbide or combinations thereof.
7 . (canceled)
8 . The super hard material of claim 1 , wherein the super hard material is thermally stable.
9 . (canceled)
10 . The super hard material of claim 1 , wherein the super hard material comprises a first layer of polycrystalline diamond with grain distribution of 0.5 to 200 micron.
11 . The super hard material of claim 1 , wherein the super hard material comprises a second layer of polycrystalline diamond with grain distribution of 0.5 to 300 micron.
12 . The super hard material of claim 1 , wherein the super hard material is bonded to a non-planar interface with the base segment.
13 . The super hard material of claim 1 , wherein the super hard material comprises a catalyzing metal concentration substantially equal or less than 40 weight percent.
14 . The replaceable wear liner of claim 1 , wherein the base segment of the super hard composite insert comprises a tapered or flange end for reception at least one of the cavities.
15 . The replaceable wear liner of claim 1 , wherein the super hard composite inserts are brazed into the cavities.
16 . The replaceable wear liner of claim 1 , wherein the super hard composite inserts are press fit into the cavities.
17 . The replaceable wear liner of claim 1 , wherein at least one insert comprises an axis that forms an angle of less than 75 degrees with a line normal to a tangent of a curvature of the crushing surface.
18 . The replaceable wear liner of claim 1 , wherein the super hard composite inserts protrude beyond the crushing surface by 0.100 to 3.00 inches.
19 . The replaceable wear liner of claim 1 , wherein the tip comprises a geometry comprising a generally elliptic paraboloid shape, a generally rounded shape, a generally conical shape, a generally pyramidal shape, a generally triangular shape, a generally frustoconical shape, a generally flat shape, a generally asymmetric shape, a generally domed shape, a generally wedge shape, a generally scoop shape, a general polygonal shape, a chamfer, a conic section, or combinations thereof.
20 . The replaceable wear liner of claim 1 , wherein the liner comprises a sensor.
21 . The replaceable wear liner of claim 20 , wherein the sensor is adapted to measure vibration, orientation, temperature, pressure, strain, stress, rotational speed, electric potential, position, corrosion, pH, particle density, particle size, wear, distance, displacement, flow rate, magnetism, or combinations thereof.
22 . The replaceable wear liner of claim 20 , wherein the sensor comprises an acoustic transducer, a nuclear transducer, an optical transducer, a capacitor, piezoelectric material, a magnetostrictive material, a solenoid, hydraulics, an actuator, or combinations thereof.
23 . The replaceable wear liner of claim 20 , wherein the replaceable wear liner further comprises a wireless transceiver.
24 . A rock crusher, comprising:
a crushing chamber disposed between two opposing walls,
at least one of the walls comprising a replaceable wear liner,
the replaceable wear liner comprising a plurality of super hard composite inserts disposed within a plurality of cavities formed in a crushing surface of the replaceable wear liner,
wherein the super hard composite inserts comprises a layer of sintered polycrystalline diamond or a sintered polycrystalline cubic boron nitride bonded at a non-planar interface with a carbide base segment attached to the replaceable wear liner.
25 . The rock crusher of claim 24 , wherein the rock crusher further comprises a sensor coupled with a wireless transceiver in communication with the replaceable wear liner.