An impact-resistant and wear-resistant composite hopper liner unit structure and a preparation method thereof

Abstract

The present invention discloses an impact-resistant and wear-resistant composite hopper liner unit structure and a preparation method thereof, comprising a mounting structure layer connected to an external structure and a wear-resistant structure layer in contact with materials, a buffer structure layer is sandwiched between the mounting structure layer and the wear-resistant structure layer; the mounting structure layer and the wear-resistant structure layer are firmly metallurgically bonded through a stabilizing structure; the stabilizing structure comprises a locking structure fixedly connected to the mounting structure layer, and a locking hole adapted to the locking structure is provided in the middle of the wear-resistant structure layer. The present invention has the characteristics of being wear-resistant, easy to install, and repairable, and can effectively avoid serious wear of the hopper, thereby solving the serious safety hazards of the hopper.

Description

Technical Field

[0001] The invention relates to the technical field of metal smelting equipment, in particular to an impact-resistant and wear-resistant composite hopper liner unit structure and a preparation method thereof. Background Art

[0002] In the metal smelting industry, hoppers are often used to transport sintered coal slag materials. In the prior art, wear-resistant liners are often used to make hoppers for transporting coal slag. Because the wear-resistant liners are less hard than the coal slag materials, after a period of operation, the wear-resistant liners cause severe local wear, and even cause the entire liner to fall off, which brings serious hidden dangers to production. The life of the wear-resistant liners is also short. Ceramic sheets for lining hoppers have become the main development direction in recent years. Ceramic sheets are fixed to the surface of the hopper by mechanical bonding and gluing. Ceramic sheets can effectively replace metal wear-resistant liners due to their high hardness, good wear resistance and long service life. However, ceramic sheets are brittle and have poor impact resistance to hard blocks mixed in the material. It is easy to cause the edges and corners of ceramic sheets to break or even fall off, resulting in severe local wear and causing serious safety hazards to production. In addition, it is difficult to repair ceramic sheets after they fall off, and the maintenance cycle is long and the cost is high. Summary of the invention

[0003] Purpose of the invention: In order to overcome the deficiencies in the prior art, the present invention provides an impact-resistant and wear-resistant composite hopper lining unit structure and a preparation method thereof, which has the characteristics of wear resistance, easy installation, and repairability, and can effectively avoid severe wear of the hopper, thereby solving the serious safety hazards of the hopper.

[0004] Technical solution: To achieve the above-mentioned purpose, the present invention provides an impact-resistant and wear-resistant composite hopper liner unit structure and a preparation method thereof, comprising an installation structure layer connected to an external structure and a wear-resistant structure layer in contact with materials, a buffer structure layer is sandwiched between the installation structure layer and the wear-resistant structure layer; the installation structure layer and the wear-resistant structure layer are firmly metallurgically bonded through a stabilizing structure; the stabilizing structure comprises a locking structure fixedly connected to the installation structure layer, and a locking hole adapted to the locking structure is opened in the middle of the wear-resistant structure layer.

[0005] Furthermore, the mounting structure layer is a metal box body, the wear-resistant structure layer is a ceramic sheet, and the buffer structure layer is an elastic structure layer formed by condensing a composite adhesive; the ceramic sheet is centrally placed in the metal box body, and the composite adhesive is filled in the gaps between the joint surfaces of the ceramic sheet and the metal box body, and the upper surface of the ceramic sheet is flush with the port surface of the metal box body.

[0006] Furthermore, the locking structure is a conical steel structure, and its small diameter end is fixed to the center of the bottom surface of the metal box body; the part of the locking hole that matches the locking structure is a conical hole.

[0007] Furthermore, the inner end of the locking hole is divided into the conical hole, and the outer end of the locking hole is divided into a cylindrical hole; a circular ceramic cover is placed centrally in the cylindrical hole, and the upper end surface of the circular ceramic cover is flush with the upper end surface of the wear-resistant structural layer; the composite adhesive is filled in the gap between the circular ceramic cover, the cylindrical hole and the locking structure.

[0008] Furthermore, the taper of the tapered hole is 2-5 degrees.

[0009] Further, the following steps are included:

[0010] Step 1: Use steel plates to stamp out a metal box body;

[0011] Step 2: sandblasting the inner wall of the metal box;

[0012] Step 3: evenly apply the composite adhesive to the bonding surface of the ceramic sheet, then install the ceramic sheet into the metal box, and press the ceramic sheet so that the composite adhesive overflows from the gap between the ceramic sheet and the frame of the metal box;

[0013] Step 4: After the composite adhesive is cured for 60-90 minutes, the locking structure is placed into the locking hole and fits with the tapered hole at the inner end thereof, and then the locking structure is welded to the bottom of the metal box body;

[0014] Step 5, evenly coating the ceramic cover with the composite adhesive, and placing it into the locking hole to be installed on the top of the locking structure;

[0015] Step six, after the composite adhesive is cured, the preparation of the composite hopper liner unit structure is completed.

[0016] Furthermore, the composite adhesive is formed by uniformly mixing two components A and B, and the mixing mass ratio of the two components A and B is 1:1.

[0017] Furthermore, component A is acrylic modified epoxy or epoxy resin; component B is modified amine or hardener.

[0018] Furthermore, the ceramic sheet is made of alumina or zirconia.

[0019] Beneficial effects: The impact-resistant and wear-resistant composite hopper liner unit structure and its preparation method of the present invention have at least the following advantages:

[0020] (1) Taking advantage of the high hardness and good wear resistance of ceramic sheets, the wear resistance of ceramic / metal composite boxes is greatly improved compared with metal wear-resistant linings, and the service life is more than 5 times the original.

[0021] (2) The ceramic / metal composite box can be directly welded and installed on the hopper surface by the user on site, which is easy to install.

[0022] (3) The bottom of the ceramic / metal composite box is welded to the surface of the hopper, and the ceramic sheet is bonded to the outer frame of the box by adhesive. Therefore, even if the material contains large hard lumps, the welded ceramic sheet can be effectively buffered in all directions, and its impact resistance is greatly improved compared to traditional lining ceramic sheets.

[0023] (4) If the ceramic / metal composite box is worn or falls off during use, the original ceramic box can be removed and a new ceramic box can be welded to achieve partial repair, greatly reducing maintenance costs.

[0024] (5) The wear-resistant ceramic / metal composite box manufactured by this process has been successfully used in coal hoppers, successfully replacing metal wear-resistant liners, greatly reducing the energy consumption caused by frequent replacement of metal liners, and making a certain contribution to reducing carbon emissions in the industry. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Attached Figure 1 This is a schematic diagram of the end surface structure of an embodiment of the present invention;

[0026] Attached Figure 2 The figure is a schematic cross-sectional structure diagram of an embodiment of the present invention. DETAILED DESCRIPTION

[0027] The present invention will be further described below in conjunction with the accompanying drawings.

[0028] As attached Figure 1-2 The impact-resistant and wear-resistant composite hopper liner unit structure and its preparation method include a mounting structure layer 1 connected to an external structure and a wear-resistant structure layer 2 in contact with materials, a buffer structure layer 3 is sandwiched between the mounting structure layer 1 and the wear-resistant structure layer 2; the mounting structure layer 1 and the wear-resistant structure layer 2 are firmly metallurgically bonded through a stabilizing structure 4; the stabilizing structure 4 includes a locking structure 41 fixedly connected to the mounting structure layer 1, and a locking hole 21 adapted to the locking structure 41 is opened in the middle of the wear-resistant structure layer 2.

[0029] This solution is a weldable and easily replaceable wear-resistant unit, which can be flatly distributed on the surface of the hopper. Adjacent units and each unit and the hopper are connected by welding the bonding surface and the installation structure layer, so as to facilitate online replacement when severe wear occurs. During repair, the severely worn wear-resistant unit can be disassembled, replaced and re-welded with a new wear-resistant unit. The wear-resistant structural layer in contact with the material needs to be made of high-hardness wear-resistant material to improve its wear resistance and extend its service life. It not only has to withstand frequent scratches from coal slag materials, but also is impacted by doped hard blocks. Therefore, this solution provides multi-directional force buffering through a buffer structure layer. The buffer structure layer 3 is wrapped around all bonding surfaces 22 of the wear-resistant structural layer 2 except the wear-resistant surface 21. When the wear-resistant surface is impacted in any direction, it will be buffered, thereby improving its impact resistance and further extending its service life.

[0030] After actual on-site laying, the installation structure layers of multiple wear-resistant units are welded together to form a grid-like frame structure welded to the surface of the hopper, which plays a good supporting role. Each wear-resistant structural layer is firmly limited in each grid by a stable structure to prevent the wear-resistant structural layer from escaping from the installation structural layer, thereby ensuring the overall stability of the constructed wear-resistant surface.

[0031] Example:

[0032] The mounting structure layer 1 is a metal box body, the wear-resistant structure layer 2 is a ceramic sheet, and the buffer structure layer 3 is an elastic structure layer formed by condensing a composite adhesive; the ceramic sheet is centrally placed in the metal box body, and the composite adhesive is filled in the gaps between the bonding surfaces of the ceramic sheet and the metal box body, and the upper surface of the ceramic sheet is flush with the port surface of the metal box body.

[0033] Preferably, the bottom end surface where the ceramic sheet and the metal box body are bonded is a corrugated structural surface, which can increase the bonding area and improve the bonding strength. The coated composite adhesive solidifies into an elastic structure between the corrugated structural surface and the inner wall surface of the metal box body, and one side of the elastic structure is flat and the other side is corrugated. Since materials such as coal slag and hard blocks roll randomly in the hopper, when the ceramic sheet is impacted by the hard block, the impact force it receives may be in any direction, but since the contacting wear-resistant surface is unique, the direction is generally consistent, and the main component of force acts on the inner end joint surface where the ceramic sheet and the metal box body are bonded, and a small part of the component of force will drive the ceramic sheet to move sideways relative to the metal box body. Then, when the impact force is transmitted through the ceramic sheet and acts on the corrugated elastic structure from the corrugated structural surface, the force received will be gradually dispersed to a direction parallel to the inner end joint surface through the raised arched area, and then diffused to the surrounding inside the elastic structure, so that most of the impact force is turned to the plane where the wear-resistant unit is laid to propagate. Through the elastic action between the internal elastic structures of multiple wear-resistant units, the effect of rapid dispersion and offset of stress is achieved, and only a small part of the impact force will directly act on the bottom end face of the metal box body. Since the bottom end face of the metal box body is directly attached to the inner wall of the hopper, the impact damage to the inner wall of the hopper can be reduced. In addition, most of the impact force is dispersed and consumed, and a small part acts on the metal box body, which makes the period of severe plastic deformation of the metal box body longer, further increasing the service life of the wear-resistant lining.

[0034] The locking structure 41 is a conical steel structure, and its small diameter end is fixed to the center of the bottom surface of the metal box body; the part of the locking hole 21 that matches the locking structure 41 is a conical hole, and the taper of the conical hole is 2-5 degrees.

[0035] The inner end of the locking hole 21 is divided into the conical hole, and the outer end of the locking hole 21 is divided into a cylindrical hole; a circular ceramic cover 5 is placed in the center of the cylindrical hole, and the upper end surface of the circular ceramic cover 5 is flush with the upper end surface of the wear-resistant structural layer 2; the gap between the circular ceramic cover 5, the cylindrical hole and the locking structure 41 is filled with the composite adhesive. The filled composite adhesive can play a buffering role and protect the welding point.

[0036] The method for preparing the composite hopper liner unit structure in the above embodiment specifically comprises the following steps:

[0037] Step 1: Use steel plate to stamp out a metal box body; the thickness of the steel plate is 1-2 mm, the metal box body is a rectangular box body, and the outer frame of the box body is chamfered by 3-5 mm;

[0038] Step 2: sandblast the inner wall of the metal box to remove oil and rust on the surface;

[0039] Step 3, evenly apply the composite adhesive to the bonding surface of the ceramic sheet, then install the ceramic sheet into the metal box body, press the ceramic sheet so that the composite adhesive overflows from the gap between the ceramic sheet and the metal box body frame, thereby ensuring that the composite adhesive fills the gaps between the ceramic sheet and the metal box body; wherein the length and width of the ceramic sheet are 1-3 mm smaller than the length and width of the inner frame of the box body;

[0040] The ceramic sheet blank is formed by hot pressing, dried, and then sintered at high temperature. After drying, the five end faces of the ceramic sheet in contact with the metal box need to be roughened by sandpaper with 80-100 mesh, and then sintered at high temperature. The purpose of roughening is to enhance the bonding strength between the end face of the ceramic sheet and the metal box and improve the impact resistance of the ceramic / metal composite box.

[0041] The ceramic sheet is a layered composite structure, and its material is aluminum oxide or zirconium oxide. Preferably, a double-layer structure design is adopted in the preparation process of the ceramic sheet blank, the bottom structural layer 22 bonded to the metal box is made of zirconium oxide, and the surface working layer 23 is made of aluminum oxide, wherein the thickness of the zirconium oxide layer accounts for 1 / 4-1 / 3 of the total thickness, and the bottom corrugation height is lower than the thickness of the zirconium oxide layer. Because the bottom surface bears the main impact force, zirconium oxide only needs to be used on the bottom surface. Furthermore, the surface working layer 23 can adopt a composite layered structure of aluminum oxide / mica / aluminum oxide, with aluminum oxide and fluorine-containing phlogopite as transition layers. When the surface layer is subjected to long-term impact and cracks appear, the cracks can be deflected, thereby improving the fracture toughness of the ceramic sheet and further improving the service life of the ceramic sheet.

[0042] Step 4: After the composite adhesive is cured for 60-90 minutes, the locking structure 41 is placed into the locking hole 21 and fits with the tapered hole at the inner end thereof, and then the locking structure 41 is welded to the bottom of the metal box body; the locking structure is a steel bowl with a tapered shape, and the bottom of the steel bowl is welded to the metal box body during welding;

[0043] Step 5: Evenly coat the ceramic cover with the composite adhesive, and place it into the locking hole 21 to install it on the top of the locking structure 41; the upper end surface of the ceramic cover is flush with the upper end surface of the ceramic sheet;

[0044] Step six, after the composite adhesive is cured, the preparation of the composite hopper liner unit structure is completed.

[0045] The composite adhesive is formed by uniformly mixing two components A and B, and the mixing mass ratio of the two components A and B is 1: 1. Preferably, component A is acrylic modified epoxy resin or epoxy resin; component B is modified amine or hardener.

[0046] The above description is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the above principles of the present invention. These improvements and modifications are also considered to be within the scope of protection of the present invention.

Claims

1. An impact-resistant and wear-resistant composite hopper liner unit structure, characterized in that: The invention comprises a mounting structure layer (1) connected to an external structure and a wear-resistant structure layer (2) in contact with a material, wherein a buffer structure layer (3) is sandwiched between the mounting structure layer (1) and the wear-resistant structure layer (2); the mounting structure layer (1) and the wear-resistant structure layer (2) are firmly metallurgically bonded via a stabilizing structure (4); the stabilizing structure (4) comprises a locking structure (41) fixedly connected to the mounting structure layer (1), and a locking hole (21) adapted to the locking structure (41) is provided in the middle of the wear-resistant structure layer (2); A plurality of the installation structure layers (1) are welded together to form a grid-like frame structure welded to the surface of the hopper; each of the wear-resistant structure layers (2) is firmly confined in each grid by a stabilizing structure (4); The mounting structure layer (1) is a metal box body, the wear-resistant structure layer (2) is a ceramic sheet, and the buffer structure layer (3) is an elastic structure layer formed by condensing a composite adhesive; the ceramic sheet is centrally placed in the metal box body, and the composite adhesive is filled in the gaps between the bonding surfaces of the ceramic sheet and the metal box body; The bottom end surface where the ceramic sheet and the metal box body are bonded is a corrugated structural surface, and the composite adhesive condenses between the corrugated structural surface and the inner wall surface of the metal box body to form an elastic structure, one side of the elastic structure is flat and the other side is corrugated; impact force in any direction is transmitted through the ceramic sheet to form multi-directional force components, the main force components act on the inner end bonding surface where the ceramic sheet and the metal box body are bonded, and a small part of the force components drives the ceramic sheet to have a lateral movement trend relative to the metal box body; the force components acting on the inner end bonding surface act from the corrugated structural surface to the elastic structure, and the force received is gradually dispersed to a direction parallel to the inner end bonding surface through the raised arched area, and then diffused to the surrounding inside the elastic structure, so as to divert most of the impact force to propagate in the plane where the wear-resistant unit is laid; the elastic action between the internal elastic structures of multiple wear-resistant units is used to quickly disperse and offset stress; The ceramic sheet is a layered composite structure, wherein the bottom structural layer (22) bonded to the metal box is made of zirconium oxide, and the surface working layer (23) is made of aluminum oxide, and the bottom corrugation height is lower than the thickness of the zirconium oxide layer; The surface working layer (23) adopts a composite layered structure of aluminum oxide / mica / aluminum oxide.

2. The impact-resistant and wear-resistant composite hopper liner unit structure according to claim 1 is characterized in that: The locking structure (41) is a conical steel structure, and its small diameter end is fixed to the center of the bottom surface of the metal box body; the part of the locking hole (21) that matches the locking structure (41) is a conical hole.

3. The impact-resistant and wear-resistant composite hopper liner unit structure according to claim 2 is characterized in that: The inner end of the locking hole (21) is divided into the conical hole, and the outer end of the locking hole (21) is divided into a cylindrical hole; a circular ceramic cover (5) is placed centrally in the cylindrical hole, and the upper end surface of the circular ceramic cover (5) is flush with the upper end surface of the wear-resistant structural layer (2); and the gap between the circular ceramic cover (5), the cylindrical hole and the locking structure (41) is filled with the composite adhesive.

4. The impact-resistant and wear-resistant composite hopper liner unit structure according to claim 3 is characterized in that: The tapered hole has a taper of 2-5 degrees.

5. The method for preparing an impact-resistant and wear-resistant composite hopper liner unit structure according to any one of claims 1 to 4, characterized in that: The following steps are involved: Step 1: Use steel plates to stamp out a metal box body; Step 2: sandblasting the inner wall of the metal box; Step 3: evenly apply the composite adhesive to the bonding surface of the ceramic sheet, then install the ceramic sheet into the metal box, and press the ceramic sheet so that the composite adhesive overflows from the gap between the ceramic sheet and the frame of the metal box; Step 4: After the composite adhesive is cured for 60-90 minutes, the locking structure (41) is placed into the locking hole (21) and fits with the tapered hole at the inner end thereof, and then the locking structure (41) is welded to the bottom of the metal box body; Step 5, evenly coating the ceramic cover with the composite adhesive, and placing it into the locking hole (21) and installing it on the top of the locking structure (41); Step six, after the composite adhesive is cured, the preparation of the composite hopper liner unit structure is completed.

6. The method for preparing an impact-resistant and wear-resistant composite hopper liner unit structure according to claim 5, characterized in that: The composite adhesive is formed by uniformly mixing two components A and B, and the mixing mass ratio of the two components A and B is 1:

1.

7. The method for preparing an impact-resistant and wear-resistant composite hopper liner unit structure according to claim 6, characterized in that: Component A is acrylic modified epoxy or epoxy resin; component B is modified amine or hardener.

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