Thermoplastic composite materials for wear surfaces and methods for making same
View Patent ↗The present techniques provide a method for making wear surfaces comprising a thermoplastic matrix blended with ceramic particles. The wear surfaces may optionally contain other materials, such as friction modifying additives. Wear surfaces formed according to these techniques may be used to protect such surfaces as the side rails of conveyor belts, the teeth of buckets used on front end loaders, rock or debris chutes, and self dumping hoppers, among others.
1. A wear surface of one layer comprising a blend of a thermoplastic matrix and one or more types of ceramic particles, wherein the ceramic particles comprise at least 50% by volume of the blend.
2. The wear surface, as set forth in claim 1 , wherein the thermoplastic matrix comprises at least one of a polyolefin, a polycarbonate, a poly(phenylene sulfide), a poly(phenylene oxide), a poly(ether ether ketone), a polyamide, or combinations thereof.
3. The wear surface, as set forth in claim 1 , wherein the ceramic particles comprise at least one of alumina, boron carbide, boron nitride, silicon carbide, silicon nitride, magnesium silicate, magnesium oxide, titanium carbide, titanium oxide, tungsten carbide, zirconia, or combinations thereof.
4. The wear surface, as set forth in claim 1 , wherein the ceramic particles comprise at least 80% by volume of the blend.
5. The wear surface, as set forth in claim 1 , wherein the ceramic particles comprise at least one of random shaped particles, substantially spherical particles, substantially rod shaped particles, substantially flat particles, or combinations thereof.
6. The wear surface, as set forth in claim 1 , wherein the ceramic particles comprise substantially flat particles that are aligned substantially parallel to a surface of the structure.
7. The wear surface, as set forth in claim 1 , wherein the ceramic particles comprise substantially spherical particles having a diameter greater than about 50 nm and less than about 500 nm.
8. The wear surface, as set forth in claim 1 , wherein the ceramic particles comprise a substantially even distribution of sizes from greater than about 0.050 mm to less than about 1 mm.
9. The wear surface, as set forth in claim 1 , comprising a protective covering for at least one of a side rail for a conveyor belt, a chute, a debris chute, a rock chute, a bearing surface, a loader bucket, a tooth of a loader bucket, a self dumping hopper, or a dumpster.
10. The wear surface, as set forth in claim 1 , comprising at least one of a side rail for a conveyor belt, a chute, a debris chute, a rock chute, a bearing surface, a loader bucket, a tooth of a loader bucket, a self dumping hopper, or a dumpster.
11. The wear surface, as set forth in claim 1 , comprising a friction reducing additive.
12. The wear surface, as set forth in claim 11 , wherein the friction reducing additive comprises at least one of graphite, poly(tetrafluoroethylene) powder, molybdenum sulfide, tungsten sulfide, boron powder, calcium carbonate, ground seashells, talc, rock dust, or combinations thereof.
13. A method for protecting a surface from wear, comprising blending of one or more types of ceramic particles and a thermoplastic matrix, wherein the ceramic particles comprise at least 50% by volume of the blend; and forming a protective surface from the blend.
14. The method, as set forth in claim 13 , wherein the thermoplastic matrix comprises at least one of a polyolefin, a polycarbonate, a poly(phenylene sulfide), a poly(phenylene oxide), a poly(ether ether ketone), a polyamide, or combinations thereof.
15. The method, as set forth in claim 13 , wherein the ceramic particles comprise at least one of alumina, boron carbide, boron nitride, silicon carbide, silicon nitride, magnesium silicate, magnesium oxide, titanium carbide, titanium oxide, tungsten carbide, zirconia, or combinations thereof.
16. The method, as set forth in claim 13 , wherein the ceramic particles comprise at least 80% by volume of the blend.
17. The method, as set forth in claim 13 , wherein the protective surface comprises at least one of a side rail for a conveyor belt, a chute, a debris chute, a rock chute, a bearing surface, a loader bucket, a tooth of a loader bucket, a self dumping hopper, or a dumpster.
18. The method, as set forth in claim 13 , wherein the protective surface comprises a protective covering for at least one of a side rail for a conveyor belt, a chute, a debris chute, a rock chute, a bearing surface, a loader bucket, a tooth of a loader bucket, a self dumping hopper, or a dumpster.
19. A conveyer belt comprising a motor driven belt; and side rails on each side of the belt, wherein the side rails comprise a blend of one or more types of ceramic particles and a thermoplastic matrix, and wherein the ceramic particles comprise at least 50% by volume of the blend.
20. The conveyor belt, as set forth in claim 19 , wherein the side rails are made from the blend.
21. The conveyor belt, as set forth in claim 19 , wherein the side rails have attached panels comprising the blend.
22. A front end loader comprising a loader bucket, wherein the loader bucket comprises a blend of one or more types of ceramic particles and a thermoplastic matrix, and wherein the ceramic particles comprise at least 50% by volume of the blend.
23. The front end loader, as set forth in claim 22 , wherein the loader bucket comprises teeth made from the blend.
24. The front end loader, as set forth in claim 22 , wherein the loader bucket comprises teeth having attached covers comprising the blend.
25. A chute for directing gravity propelled objects to a destination comprising a blend of one or more types of ceramic particles and a thermoplastic matrix, and wherein the ceramic particles comprise at least 50% by volume of the blend.
26. The chute, as set forth in claim 25 , comprising attached panels made from the blend.
27. The chute, as set forth in claim 25 , wherein the chute is molded from the blend.
28. The chute, as set forth in claim 25 , comprising either a rock chute or a debris chute.
29. A self-dumping hopper comprising a blend of one or more types of ceramic particles and a thermoplastic matrix, and wherein the ceramic particles comprise at least 50% by volume of the blend.
30. The self-dumping hopper, as set forth in claim 29 , comprising attached panels made from the blend.
31. The self-dumping hopper, as set forth in claim 29 , comprising a hopper bucket made from the blend.