Belt conveyor scraper blade and method for manufacturing same

Abstract

The present disclosure relates to a belt conveyor scraper blade (100) configured to scrape material from a belt conveyor surface (24), the belt conveyor scraper blade (100) comprising: a support shell structure (110) presenting a scraper tip (112) at a first end (111) and a mounting base (114) at an opposite second end (113), the support shell structure (110) tapering toward the scraper tip (112) at at least the first end (111); and one or more scraper elements (120a-c) disposed within the support shell structure (110) to at least partially fill an interior of the support shell structure (110) at the first end (111), the support shell structure (110) being made of a first material and the one or more scraper elements (120a-c) being made of a second material, the first and second materials being different. The present disclosure further relates to a method for manufacturing a belt conveyor scraper blade.

Description

[Technical Field]

[0001] The present invention relates to a belt conveyor scraper blade and a method for manufacturing a belt conveyor scraper blade. [Background technology]

[0002] Scraper blades for belt conveyors are used to clean belt conveyors from materials that have accumulated on them and remain on the belt conveyor even after the conveyed material has left the belt conveyor. Many parameters are important for the functionality of a scraper blade. A scraper blade must have a stable structure to maintain its shape while under stress during use. A scraper blade must also have good wear characteristics to reduce downtime caused by scraper replacement. If scraper blades need to be replaced too frequently, this is both economical and environmentally problematic due to the waste of resources. When a scraper blade for a belt conveyor is in operation, it will gradually wear out as a result of the frictional forces exerted on it by the moving belt conveyor. At the end of its useful life, a large portion of the scraper blade will have been removed by wear, making it time to replace it to maintain the required belt conveyor cleaning. After replacement, what's left of the old scraper blade must be disposed of. A problem with scraper blades in the art is that once they reach the end of their useful life, their remaining portions constitute a significant amount of waste. Therefore, there is a need in the art for improved scraper blades that reduce the amount of waste during replacement. Summary of the Invention

[0003] It is an object to mitigate, alleviate or eliminate one or more of the above-identified deficiencies and drawbacks in the art singly or in any combination. These and other objects are met, at least in part, by the invention as defined in the independent claims. Preferred embodiments are set out in the dependent claims.

[0004] According to a first aspect, there is provided a belt conveyor scraper blade having an extension along a scraper axis and configured to scrape material from a belt conveyor surface along a scraping area extending parallel to the scraper axis, the scraper blade comprising: Belt conveyor scraper blades a support shell structure presenting a scraper tip at a first end and a mounting base at an opposite second end, the support shell structure tapering at least at the first end toward the scraper tip; one or more scraper elements disposed within the support shell structure at the first end to at least partially fill the interior of the support shell structure; wherein the belt conveyor scraper blade is structured and configured to wear during use, and the one or more scraper elements are positioned relative to the support shell structure such that the one or more scraper elements are completely or partially worn at the end of the useful life of the belt conveyor scraper blade; A belt conveyor scraper blade is provided, wherein the support shell structure is made of a first material and the one or more scraper elements are made of a second material, the first and second materials being different.

[0005] A belt conveyor scraper blade can be advantageous because its support shell structure allows for selective filling of the support shell structure with scraper elements. By selectively filling the portions of the support shell structure that will be worn out by the end of the belt conveyor scraper blade's useful life, the total amount of material required to manufacture the belt conveyor scraper blade is reduced, allowing a larger portion of the belt conveyor scraper blade to be used before the remaining portion is disposed of as waste. Using two different materials also allows for material properties to be selected independently of each other. This can allow a support shell structure with one preferred characteristic to contribute to one function of the belt conveyor scraper blade, while scraper elements with other characteristics contribute to another function.

[0006] The supporting shell structure should be interpreted as an outer layer having a finite thickness. Therefore, the supporting shell structure is hollow. One purpose of the supporting shell structure is to define the shape of the belt conveyor scraper blade and support one or more scraper elements. Another purpose of the supporting shell structure is to provide structural integrity to the belt conveyor scraper blade. The advantage of the shell structure is that it allows for minimizing the amount of material used to maintain the structural shape of the belt conveyor scraper blade. This can minimize both the amount of material used for the supporting shell structure and the amount of material used for one or more scraper elements. As a result, the belt conveyor scraper blade has a smaller environmental footprint and can be more economically beneficial.

[0007] During use, belt conveyor scraper blades will experience wear at the contact points between the scraper blade and the belt conveyor. Wear will occur at the location of the scraper where it contacts the belt conveyor. A newly replaced belt conveyor scraper blade will therefore first experience wear of the support shell structure until this outer shell layer is worn away and the belt conveyor surface reaches the scraper elements of the scraper. Therefore, the support shell structure may be subject to wear either alone or together with the scraper elements. At the end of the useful life of a belt conveyor scraper blade, one or more scraper elements will be completely or partially worn away. Therefore, when replacing a belt conveyor scraper blade, the waste will primarily or only comprise the remaining portion of the support shell structure. Because the remaining portion of the support shell structure is not intended to perform any scraping, it may be structured and configured to provide only structural integrity, which allows for a design with a reduced amount of material compared to scrapers in the art.

[0008] The belt conveyor scraper blade is intended to be positioned relative to the belt conveyor so that its upper end contacts the belt conveyor along a scraping area. The scraping area extends parallel to the extension of the belt conveyor scraper blade. The scraping area also extends generally parallel to the rotation axis of the belt conveyor. This implies that the scraping area extends generally transversely to the direction of movement of the belt conveyor. Typically, multiple belt conveyor scraper blades are arranged adjacent to each other to form a common belt conveyor scraper structure of sufficient length to scrape a portion or the entire width of the belt conveyor.

[0009] As will be readily recognized by those skilled in the art, the working portion of a belt conveyor scraper blade that abuts the belt conveyor will gradually move as the belt conveyor scraper blade wears during use. However, as used herein, the terms "scraper tip," "first end," etc. will always refer to an unworn, i.e., unused, belt conveyor scraper blade.

[0010] In some embodiments, the support shell structure completely surrounds the one or more scraper elements in a direction transverse to the scraper axis, which implies that the support shell structure completely surrounds the one or more scraper elements in a plane transverse to the scraper axis, so that the one or more scraper elements are completely surrounded in two dimensions of the three-dimensional space transverse to the scraper axis.

[0011] The directions transverse to the scraper axis include a first direction extending from the first end to the second end of the support shell structure and a second direction extending generally along the direction of travel of the belt conveyor at a connection point between the belt conveyor scraper blades. The support shell structure will surround one or more scraper elements from each side in the first direction and from each side in the second direction.

[0012] The support shell structure completely surrounds one or more scraper elements in two directions, ensuring stability throughout the belt conveyor scraper blade's service life. Some portion of the support shell structure will remain in place to maintain the belt conveyor scraper blade's structural shape. This ensures that the belt conveyor scraper blade can maintain close contact with the belt conveyor throughout its service life.

[0013] It is emphasized that this does not imply that the support shell structure completely surrounds one or more scraper elements in three dimensions: the support shell structure may be structured such that it does not surround one or more scraper elements along the scraper axis.

[0014] According to some embodiments, the support shell structure has a constant cross-sectional shape along the scraper axis.

[0015] According to some embodiments, the support shell structure is manufactured by an extrusion process, an injection molding process, or a 3D printing process.

[0016] The extrusion process is a reliable process for producing support shell structures with a consistent cross-sectional shape. It allows for the production of elements with relatively complex shapes and hollow spaces. It also allows for the production of elements with relatively long lengths. This may allow for the production of long belt conveyor scraper blades that allow a single scraper blade to cover the entire scraping width. The injection molding process is also considered a reliable process for producing support shell structures. It is a versatile technique and allows for the production of highly complex shapes. Specifically, it may allow for the production of support shell structures with cross-sectional shapes that vary along the scraper axis. The 3D printing process is also considered a reliable process for producing support shell structures. While the production time may not be as fast, it allows for the production of highly complex shapes. Furthermore, design modifications are more easily implemented because specialized elements, such as tailored molds used in extrusion and injection molding processes, do not need to be designed and fabricated.

[0017] According to some embodiments, the second material comprises a polymer.

[0018] According to some embodiments, the second material comprises a polyurethane or a thermoplastic elastomer.

[0019] Polyurethane can provide low friction, high abrasion resistance, and high strength. Another advantage is that polyurethane-based scraper elements can be formed by molding. The second material can be a polyurethane composite. Thermoplastic elastomers (TPEs) exhibit advantages typical of both rubber-like and plastic materials. The benefit of using thermoplastic elastomers can be their ability to stretch to moderate elongations and return to nearly their original shape, which can result in a longer lifespan and better physical range than many other materials. Another advantage of thermoplastic elastomers is that, while most elastomers are thermosets, thermoplastic elastomers, in contrast, are relatively easy to use in manufacturing, for example, by injection molding and extrusion processes. The thermoplastic elastomer can be thermoplastic polyurethane (TPU). Thermoplastic elastomers include at least styrene block copolymers, TPS (TPE-s), thermoplastic polyolefin elastomers, TPO (TPE-o), thermoplastic vulcanizates, TPV (TPE-v or TPV), thermoplastic polyurethanes, TPU (TPU), thermoplastic copolyesters, and TPC (TPE-E), and thermoplastic polyamides, TPA (TPE-A). Examples of TPE materials from the block copolymer group are CAWITON, THERMOLAST K, THERMOLAST M, Arnitel, Hytrel, Dryflex, Mediprene, Kraton, Pibiflex, Sofprene, and Laprene, among others. Among these styrene block copolymers (TPE-s), CAWITON, THERMOLAST K, THERMOLAST M, Sofprene, Dryflex, and Laprene are examples of thermoplastic polyurethanes (TPUs). Laripur, Desmopan, or Elastollan are examples of thermoplastic polyurethanes (TPUs). Examples of TPV materials are Sarlink, Santoprene, Termoton, Solprene, THERMOLAST V, Vegaprene, or Forprene. Examples of thermoplastic olefin elastomer (TPO) compounds are For-Tec E or Engage.

[0020] The second material may also comprise other types of material suitable for scraping a conveyor belt, such as rubber.

[0021] It is also conceivable to incorporate additional compounds into the material. For example, carbide may be suitable for some embodiments of belt conveyor scraper blades due to its high wear resistance. In other words, the scraper element may be made from a material containing carbide powder. The carbide powder may be mixed with a polymer material such as polyurethane. It is also conceivable to provide a scraper element containing other ceramic powders or graphene powder.

[0022] According to some embodiments, the first material is biodegradable and / or bio-based. Providing a biodegradable and / or bio-based first material allows for further reduction of environmental impact. When the remaining portion of the worn scraper is replaced, it can be disposed of in a sustainable manner. For example, it can be shredded into smaller pieces and composted. Thus, providing these materials can completely eliminate or at least reduce landfill growth.

[0023] In some embodiments, the first material has a higher hardness than the second material. The hardness of the materials may be measured using a Shore durometer. The second material may have a hardness of 50 to 95° Shore A, typically more preferably 70° Shore A. When the first material is harder than the second material, the support shell structure can provide the stability needed for the belt conveyor scraper blade to maintain its shape during use.

[0024] The increased stability of the support shell structure can be advantageous because it allows for the use of softer materials for the scraper elements, even materials that are too hard to maintain their shape during use. Softer materials are often more abrasion-resistant, which increases the lifespan of the belt conveyor scraper blade. The benefit of increased lifespan is that belt conveyor scraper blades do not need to be replaced as frequently, reducing the need for belt conveyor maintenance.

[0025] According to some embodiments, the first material comprises a polymer.

[0026] According to some embodiments, the first material comprises one or more from the list of thermoplastic elastomer, polyvinyl chloride, acrylonitrile styrene acrylate, and polyethylene.

[0027] The first material can be a thermoplastic polymer. One suitable thermoplastic polymer can be acrylonitrile styrene acrylate (ASA), also known as acrylic styrene acrylonitrile, an amorphous thermoplastic developed as a replacement for acrylonitrile butadiene styrene (ABS). It is an acrylate rubber-modified styrene acrylonitrile copolymer. It has high UV resistance and mechanical properties, making it a suitable material for use in extrusion processes.

[0028] The first material may comprise a biodegradable thermoplastic elastomer. The first material may be a composition of two or more compounds. The two or more compounds may be selected from the list of thermoplastic elastomers, polyvinyl chloride, or polyethylene, but may alternatively be selected from other compounds.

[0029] The first and second materials may each be a composition comprising the same compound. For example, the first and second materials may each comprise a specific thermoplastic elastomer or a polyurethane. The difference between the first and second materials in this case depends on the composition, where the other compound portions of the composition may be different.

[0030] Alternatively or additionally, the first and second materials may comprise different species within the same material family, for example, the first material may comprise a first thermoplastic elastomer and the second material may comprise a second, different thermoplastic elastomer.

[0031] According to some embodiments, the interior of the support shell structure comprises multiple sections, each defining a respective interior volume. The multiple sections may include one or more scraper sections, each filled with a respective one of one or more scraper elements, and one or more hollow sections. The multiple sections may be advantageous for achieving a specific configuration of the belt conveyor scraper blade. For example, it may be advantageous to only fill with scraper elements those sections that are worn away during use. This would reduce the amount of waste. Which sections are filled with scraper elements may depend on the contact slope between the belt conveyor scraper blade and the belt conveyor. The filled sections may also be determined by the selection of the first and second materials. The hollow sections may be advantageous because they further reduce the overall volume of the belt conveyor scraper blade and allow for a reduction in the volume of waste when a worn belt conveyor scraper blade is disposed of at the end of its useful life. Another advantage of the hollow sections may be that they make the belt conveyor scraper blade easier to handle due to their lighter weight. The one or more hollow portions can be through openings extending through the support structure along the scraper axis. The one or more scraper portions can be through openings extending through the support structure along the scraper axis, each of the through openings being filled with a respective one of the one or more scraper elements.

[0032] According to some embodiments, the one or more hollow portions include a first hollow portion located within the mounting base. The first hollow portion can be used to mount a belt conveyor scraper blade. It can also be used to attach a means for mounting the belt conveyor scraper blade.

[0033] In some embodiments, the one or more hollow portions include a second hollow portion located between the mounting base and the one or more scraper portions, which contributes to more efficient use of material.

[0034] According to some embodiments, adjacent portions of the plurality of sections are separated from one another by a separating structure that interconnects opposing walls of the support shell structure. The opposing wall may be a wall extending along the scraper axis, extending between the scraper tip at the first end and the mounting base at the second end. The separating structure may be advantageous for providing increased stability to the support shell structure. It may also further increase the likelihood that the belt conveyor scraper blade will maintain its shape during use. A further advantage of the separating structure may be that it provides a clear separation between the sections, which facilitates manufacturing a belt conveyor scraper blade with desired shapes and characteristics. As used herein, the term "separating structure" refers to any structure that defines a boundary between two adjacent areas / volumes. The separating structure may be an interior wall.

[0035] According to a second aspect, there is provided a belt conveyor scraper assembly for scraping material from a belt conveyor surface, the belt conveyor scraper blade comprising: a plurality of belt conveyor scraper blades according to a first aspect; a support shaft structured and configured to support a plurality of belt conveyor scraper blades; tensioning means configured to apply a torque or force on the support shaft to urge the plurality of belt conveyor scraper blades against the belt conveyor surface; Equipped with.

[0036] According to a third aspect, there is provided a method of manufacturing a belt conveyor scraper blade, comprising: a) fabricating a support shell structure made of a first material having a scraper tip at a first end and a mounting base at an opposite second end, the support shell structure tapering at least at the first end toward the scraper tip; b) disposing one or more scraper elements made of a second material within the support shell structure to at least partially fill the interior of the support shell structure at the first end; A method is provided, comprising:

[0037] According to some embodiments, manufacturing the support shell structure is accomplished by an extrusion process, an injection molding process, or a 3D printing process.

[0038] According to some embodiments, the step of disposing one or more scraper elements within the support shell structure comprises: providing a second material in liquid form into the support shell structure to at least partially fill the interior of the support shell structure at the first end; whereby the second material bonds with the first material of the support shell structure to form a coherent structure during cooling.

[0039] According to some embodiments of the method, the first and second materials are different.

[0040] The support shell structure can be manufactured as a whole in a single manufacturing step, or alternatively, in sections that are subsequently attached to each other in a second step to form the support shell structure. For example, the support shell structure can be manufactured via an extrusion process by fabricating two or more separate sections, which are then attached to each other. This modular manufacturing process can be beneficial for longer belt conveyor scraper blades, which can be difficult to manufacture using an extrusion process, for example. The modular manufacturing process offers an additional advantage in that it allows for reinforcing structures that do not extend along the scraper direction to be provided within the support shell structure prior to installing the modules together. This may further allow for the use of only a portion of the soon-to-be supporting shell structure as a mold when introducing a second material for one or more scraper elements. When two or more such sections are filled with the second material, which is then combined with the first material to form a coherent structure, the sections can be attached to each other to provide a complete belt conveyor scraper blade.

[0041] The effects and features of the second and third aspects are largely similar to those described above in relation to the first aspect. The embodiments mentioned in relation to the first aspect are largely compatible with the second and third aspects. It is further noted that the inventive concept relates to all possible combinations of features unless expressly stated otherwise.

[0042] Further scope of applicability of the present disclosure will become apparent from the detailed description given below. It should be understood, however, that the detailed description and specific examples, while indicating preferred versions of the disclosure, are given by way of illustration only, since various changes and modifications within the scope of the disclosure will become apparent to those skilled in the art from the detailed description.

[0043] Therefore, it is to be understood that the present disclosure is not limited to the particular component parts of such devices and steps of such methods, as the described devices or methods may vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting. It should be noted that, as used in this specification and the appended claims, the articles "a," "an," "the," and "said" are intended to mean that there are one or more of an element, unless the context dictates otherwise. Thus, for example, reference to "a unit" or "the unit" may include several devices, and the like. Furthermore, the words "comprising," "including," "containing," and similar expressions do not exclude other elements or steps.

[0044] The present disclosure will now be described in more detail, by way of example, with reference to the accompanying drawings which show presently preferred embodiments of the disclosure. [Brief explanation of the drawings]

[0045] [Figure 1] FIG. 1 is a perspective view of a belt conveyor scraper assembly according to an exemplary embodiment of the present disclosure. [Figure 2] FIG. 1 is a perspective view of a belt conveyor scraper blade according to an exemplary embodiment of the present disclosure. [Figure 3A] FIG. 3 is a perspective view of a support shell structure of the belt conveyor scraper blade of FIG. [Figure 3B] FIG. 3 is a perspective view of a scraper element of the belt conveyor scraper blade of FIG. 2. [Figure 4A] FIG. 3 is a cross-sectional view of the support shell structure of the belt conveyor scraper blade of FIG. [Figure 4B] FIG. 3 is a cross-sectional view of a scraper element of the belt conveyor scraper blade of FIG. 2. [Figure 5A]FIG. 10 is a cross-sectional view of an alternative illustrative embodiment of a belt conveyor scraper blade of the present disclosure. [Figure 5B] FIG. 10 is a cross-sectional view of an alternative illustrative embodiment of a belt conveyor scraper blade of the present disclosure. [Figure 5C] FIG. 10 is a cross-sectional view of an alternative illustrative embodiment of a belt conveyor scraper blade of the present disclosure. [Figure 6] 1 is a flow chart illustrating different steps in a method for manufacturing a belt conveyor scraper blade according to the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0046] The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which presently preferred embodiments of the disclosure are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided for thoroughness and completeness, and to fully convey the scope of the disclosure to those skilled in the art.

[0047] Belt conveyors are used to transport large amounts of material from one location to another. In certain applications, for example in the mining industry, belt conveyors are used to transport materials such as sand, ore, gravel, coal, minerals, and the like. In such applications, materials tend to adhere to the belt conveyor surface, which therefore needs to be cleaned.

[0048] One known solution for keeping belt conveyors clean is to mechanically remove material that has accumulated on the belt surface. An example of this type of cleaning system is illustrated in FIG. 1 in the form of a belt conveyor scraper assembly 10. The belt conveyor scraper assembly 10 includes a plurality of belt conveyor scraper blades 100 arranged adjacent to one another to form a common belt conveyor scraper structure of sufficient length to scrape the entire width, or at least a majority of the width, of the belt conveyor surface 24. The belt conveyor scraper assembly 10 includes a support shaft 26 structured and configured to support the plurality of belt conveyor scraper blades 100. The belt conveyor scraper blades 100 are described more thoroughly in connection with FIG. 2. The support shaft 26 is configured to press the plurality of belt conveyor scraper blades 100 against the belt conveyor surface 24 via suitable tensioning means 34. The tensioning means 34 is configured to apply a torque or force on the support shaft 26 such that the support shaft 26 presses the belt conveyor scraper blade 100 toward the belt conveyor surface 24. As will be recognized by those skilled in the art, there are many such suitable tensioning means known in the art, for example, based on biasing by a spring or weight. For purposes of this disclosure, the tensioning means 34 is therefore only conceptually illustrated in FIG. 1 . As the belt conveyor surface 24 moves relative to the belt conveyor scraper blade 100, the scraper blade 100 will scrape the adhering material from the belt conveyor surface 24. The belt conveyor scraper blade 100 is attached to a mounting element 28 that is rigidly fastened to a square tube 27, which is in turn attached to the support shaft 26. The mounting element 28 and the belt conveyor scraper blade 100 mounted thereon can thus be easily and quickly installed and removed as a single unit. The belt conveyor scraper blades 100 are attached to the support shaft 26 via respective mounting bases 114 (see, e.g., FIG. 2 ). The mounting bases 114 may be shaped to form a locking engagement with the support shaft 26.The belt conveyor scraper blade 100 is intended to be positioned relative to the belt conveyor surface 24 so that its upper end 111 contacts the belt conveyor surface 24 along a scraping area 16 (see dotted line in FIG. 1 ). The scraping area 16 extends parallel to the extension of the belt conveyor scraper blade 100. The scraping area 16 also extends generally parallel to the rotation axis R of the belt conveyor pulley 25.

[0049] 2, 3A-3B, and 4A-4B illustrate a belt conveyor scraper blade 100 according to an illustrative embodiment. The belt conveyor scraper blade 100 includes a support shell structure 110 extending along a scraper axis A and presenting a scraper tip 112 at a first end 111 and a mounting base 114 at an opposite second end 113. The support shell structure 110 tapers toward the scraper tip 112 at at least the first end 111. The support shell structure 110 has an outer layer having a finite thickness. Thus, the support shell structure 110 may be hollow. One purpose of the support shell structure 110 is to define the shape of the belt conveyor scraper blade 100 and to support one or more scraper elements 120a-c.

[0050] The support shell structure of the belt conveyor scraper blade 100 has a constant cross-sectional shape along the scraper axis A. This provides certain advantages for manufacturing the belt conveyor scraper blade 100, as will be described in more detail below.

[0051] The interior of the support shell structure 110 includes a plurality of sections 133a-f (see FIG. 3A), each defining a respective interior volume 132a-f. The plurality of sections 133a-f includes three scraper sections 133a-c and three hollow sections 133d-f. The number of scraper sections 133a-c and the number of hollow sections 133d-f may vary between embodiments. The sections 133a-f are distinguished by whether they are filled with scraper elements 120a-c. If the section is filled with scraper elements 120a-c, it is referred to herein as a scraper section 133a-c. If the section is empty and does not include scraper elements 120a-c, it is referred to herein as a hollow section 133d-f. In this illustrative embodiment, three different scraper elements 120a, 120b, and 120c are used. The multiple sections 133a-f are separated from one another by isolation structures 140a-e, which interconnect the opposing walls 116a, 116b of the support shell structure 110. The isolation structures 140a-e can be walls that completely separate adjacent sections 133a-f from one another. The isolation structures 140a-e are connected at each end to one of the opposing walls 116a, 116b. In this illustrative embodiment, the opposing walls 116a, 116b are defined as walls extending from the scraper tip 112 to the mounting base 114. In other embodiments, the isolation structures 140a-e can extend between other walls of the support shell structure 110. The use of multiple sections 133a-f allows for many different designs of the belt conveyor scraper blade. It is also possible to adapt the belt conveyor scraper blade to different belt conveyor scraper assemblies 10. The hollow portions 133d-f reduce the weight of the belt conveyor scraper blade 100, making it easier to handle. A further advantage of the separation structures 140a-e is that they provide a clear separation between the portions, making it easier to manufacture belt conveyor scraper blades with desired shapes and characteristics. The hollow portions 133d-f in FIG. 2 consist of a first hollow portion 133f located within the mounting base 114 and two hollow portions 133d and 133e located between the mounting base 114 and the scraper portions 133a-c.To reduce the amount of waste generated when replacing worn belt conveyor scraper blades, preferably only the portions that are worn away during use are filled with scraper elements 120a-c. Which of the portions is worn away may depend on the slope between the belt conveyor scraper blade 100 and the belt conveyor. Thus, the slope may be a design parameter when determining which of the portions 133a-f should be filled with scraper elements 120a-c.

[0052] The support shell structure 110 completely surrounds the three scraper elements 120a-c such that the three scraper elements 120a-c are completely surrounded in two dimensions of a three-dimensional space transverse to the scraper axis A. The three scraper elements 120a-c, however, are not surrounded in the direction of the scraper axis A. Directions transverse to the scraper axis A include a first direction L1 extending from the second end 113 to the first end 111 of the support shell structure 110 and a second direction L2 extending orthogonal to the first direction and the scraper axis A, i.e., between the two opposing walls 112a, 112b. The support shell structure 110 will surround one or more scraper elements 120a-c from each side in the first direction L1 and from each side in the second direction L2.

[0053] The support shell structure 110 may have a plurality of fins 160 on one of its walls extending from the scraper tip 112 to the mounting base 114 to provide a stepped or serrated surface. Each of the fins 160 extends along the scraper axis and covers the entire extension E of the belt conveyor scraper blade 100.

[0054] 5A-5D, four alternative embodiments of a belt conveyor scraper blade are disclosed. As will be readily recognized by one of ordinary skill in the art upon viewing the figures, each of these alternative embodiments shares certain features with the above-described belt conveyor scraper blade 100. To enhance clarity, features common to the first embodiment will be assigned the same reference numeral, whereas features unique to a particular illustrative embodiment will have a higher-order reference numeral.

[0055] 5A discloses an illustrative embodiment having three separated structures 140c-e and three hollow portions 133d-f, but one scraper portion 233. The single scraper portion 233 is filled with a single scraper element 220. As will be readily recognized by those skilled in the art, the volume of the scraper element 220 can be similar to or equal to the total volume of the scraper elements 120a-c of the belt conveyor scraper blade 100 of FIGS.

[0056] 5B illustrates a belt conveyor scraper blade 300 according to yet another illustrative embodiment. Belt conveyor scraper blade 300 differs from belt conveyor scraper blade 100 in that separation structures 340a, 340b are provided at a more acute angle of inclination. As a result, the geometry of portions 333a-c and the scraper elements 320a-c housed therein will differ from the geometry of portions 133a-c and the corresponding scraper elements 120a-c of belt conveyor scraper blade 100. The inclined separation structures 340a, 340b may be advantageous in some applications to enhance the structural integrity of belt conveyor scraper blade 300.

[0057] 5C illustrates a belt conveyor scraper blade 400 according to yet another illustrative embodiment. Belt conveyor scraper blade 400 is similar to belt conveyor scraper blade 200, except that belt conveyor scraper blade 400 lacks a separation structure at the bottom of the scraper. As such, belt conveyor scraper blade 400 has two separation structures 140c, 140e, two hollow portions 433, 133f, and one scraper portion 233.

[0058] The material characteristics of the belt conveyor scraper blade of the present invention will now be described in detail. This will be done with reference to a first illustrative embodiment, the belt conveyor scraper blade 100, but the description is equally valid for the other illustrative embodiments described herein and within the scope of the claims. When designing the belt conveyor scraper blade 100, an important factor is the material. The support shell structure 110 is made of a first material, and the scraper elements 120 are made of a second material. The first and second materials are different. Using two different materials allows the material properties to be selected independently of each other. This may allow the support shell structure 110 with one preferred characteristic to contribute to one function of the belt conveyor scraper blade 100, while the scraper elements 120a-c with other characteristics contribute to another function.

[0059] The purpose of the support shell structure 110 is to provide structural integrity to the belt conveyor scraper blade 100. An advantage of the support shell structure 110 is that it allows for minimizing the amount of material required to maintain the structural shape of the belt conveyor scraper blade 100. This may allow for minimizing both the amount of material used for the support shell structure 110 and the amount of material used for one or more scraper elements 120a-c. The first material from which the support shell structure is made may be biodegradable and / or bio-based. Providing a biodegradable and / or bio-based first material further reduces environmental impact. When the worn-out scraper remaining portion is replaced, it can be disposed of sustainably. For example, it can be shredded into smaller elements and composted. Providing these materials may completely eliminate or at least reduce landfill growth. The first material may comprise one or more of the following: thermoplastic elastomer, polyvinyl chloride, acrylonitrile styrene acrylate, and polyethylene. The first material can be a thermoplastic polymer. One suitable thermoplastic polymer can be acrylonitrile styrene acrylate (ASA), also known as acrylic styrene acrylonitrile, an amorphous thermoplastic developed as a replacement for acrylonitrile butadiene styrene (ABS). It is an acrylate rubber-modified styrene acrylonitrile copolymer. It has high UV resistance and mechanical properties, making it a suitable material for use in extrusion processes.

[0060] The first material may comprise a biodegradable material, such as a biodegradable thermoplastic elastomer. The first material may be a composition of two or more compounds. The two or more compounds may be selected from the list of thermoplastic elastomer, polyvinyl chloride, acrylonitrile styrene acrylate (ASA), and polyethylene, but may alternatively be selected from other compounds.

[0061] The purpose of the scraper elements 120a-c is to perform a scraping action on the belt conveyor surface 24. Important properties for the scraper elements 120a-c may be wear resistance and flexibility to reduce the risk of the scraper elements 120a-c damaging the belt conveyor surface 24. The second material from which the scraper elements 120a-c are made may comprise a polymer, such as polyurethane or a thermoplastic elastomer. Alternatively, the second material may comprise a carbide material, for example, in the form of a carbide powder mixed into a further material, such as a polymer material. Polyurethane may offer low friction, high wear resistance, and high strength. Another advantage is that polyurethane-based scraper elements can be formed by molding. The second material may be a polyurethane composite material. Thermoplastic elastomers (TPEs) exhibit advantages typical of both rubber-like and plastic materials. The benefit of using a thermoplastic elastomer may be its ability to stretch to moderate elongations and return to nearly its original shape, resulting in a longer lifespan and better physical range than many other materials. Another advantage of thermoplastic elastomers is that, while most elastomers are thermosets, thermoplastic elastomers, in contrast, are relatively easy to use in manufacturing, for example, by injection molding and extrusion processes. The thermoplastic elastomer may be thermoplastic polyurethane (TPU). Carbonized materials may be suitable for some embodiments of belt conveyor scraper blades due to their high abrasion resistance. The second material may also comprise other types of materials suitable for scraping belt conveyors, such as rubber.

[0062] The first material may have a higher hardness than the second material. The hardness of the materials may be measured using a Shore durometer. The second material may have a hardness of 50 to 95° Shore A, typically more preferably 70° Shore A. When the first material is harder than the second material, the support shell structure can provide the stability needed for the belt conveyor scraper blade to maintain its shape during use.

[0063] The support shell structure of the belt conveyor scraper blade of the present disclosure can be manufactured by an extrusion process. The extrusion process is well known in the art and therefore will not be described in detail herein. The extrusion process is a reliable process for providing a product with a consistent cross-sectional shape. Such a product can be the support shell structure and / or scraper element(s) of the present disclosure. Using the extrusion process, it can be easy to manufacture the support shell structure, which is advantageous from an economic standpoint.

[0064] A method of manufacturing a belt conveyor scraper blade will now be described with reference to Figure 5. The method comprises: a) Step S502 of manufacturing a support shell structure 110 made of a first material, the support shell structure 110 having a scraper tip 112 at a first end 111 and a mounting base 114 at an opposite second end 113, the support shell structure 110 tapering at least at the first end 111 towards the scraper tip 112; b) step S504 of disposing one or more scraper elements 120a-c made of a second material within the support shell structure 110 to at least partially fill the interior of the support shell structure 110 at the first end 111; Equipped with.

[0065] Step S502 of manufacturing the support shell structure 110 may be accomplished by an extrusion process, an injection molding process, or a 3D printing process.

[0066] The step of disposing one or more scraper elements 120a-c within the support shell structure 110 includes: providing a second material in liquid form into the support shell structure 110 to at least partially fill the interior of the support shell structure 110 at the first end 111; whereby the second material bonds with the first material of the support shell structure 110 to form a coherent structure during cooling.

[0067] As previously mentioned, the first and second materials are different. This does not, however, exclude that both the first and second materials may comprise the same compound, such as polyethylene. The first and second materials may each be a respective composition of two or more compounds, where one of these two or more compounds is common to both materials.

[0068] The figure illustrates the belt conveyor scraper blade 100 before use. The belt conveyor scraper blade 100, however, is structured and configured to wear during use, with one or more scraper elements 120 a-c positioned relative to the support shell structure 110 such that the one or more scraper elements 120 a-c are fully or partially worn away at the end of the useful life of the belt conveyor scraper blade 100. During use, the belt conveyor scraper blade 100 will experience wear at the point of contact between the belt conveyor scraper blade 100 and the belt conveyor surface 24. Wear will occur at the location of the belt conveyor scraper blade 100 that contacts the belt conveyor surface 24, i.e., the scraping region 16. A newly replaced belt conveyor scraper blade 100 will therefore first experience wear of the support shell structure 110 until this outer shell layer is worn away and the belt conveyor surface 24 reaches the upper scraper element 120a of the belt conveyor scraper blade 100. From this, the scraper element 120a and the support shell structure 110 may be worn away individually or together. Once worn away, the belt conveyor surface 24 reaches the second-to-top scraper element 120b of the belt conveyor scraper blade 100 and begins to wear that scraper element 120b. At the end of the useful life of the belt conveyor scraper blade 100, one or more of the scraper elements 120a-c will be completely or partially worn away. From this, when replacing the belt conveyor scraper blade 100, the waste will primarily or only comprise the remaining portion of the support shell structure 110. Therefore, the appearance of a used belt conveyor scraper blade 100 may be very different from the appearance of the belt conveyor scraper blade in the figures.

[0069] Those skilled in the art will recognize that the present invention is by no means limited to the preferred embodiments described above. On the contrary, many modifications and variations are possible within the scope of the appended claims. Additionally, variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.

Claims

1. A belt conveyor scraper blade (100) having an extension along a scraper axis (A) and configured to scrape material from a belt conveyor surface (24) along a scraping area (16) extending parallel to said scraper axis (A), comprising: The belt conveyor scraper blade (100) a support shell structure (110) presenting a scraper tip (112) at a first end (111) and a mounting base (114) at an opposite second end (113), the support shell structure tapering at least at said first end (111) towards said scraper tip (112); one or more scraper elements (120a-c) disposed within said support shell structure (110) to at least partially fill the interior of said support shell structure (110) at said first end (111); wherein the belt conveyor scraper blade (100) is structured and configured to wear during use, and one or more of the scraper elements (120a-c) are positioned relative to the support shell structure (110) such that one or more of the scraper elements (120a-c) are completely or partially worn away at the end of the useful life of the belt conveyor scraper blade (100); A belt conveyor scraper blade (100) wherein the support shell structure (110) is made of a first material and one or more of the scraper elements (120a-c) are made of a second material, the first and second materials being different.

2. 2. The belt conveyor scraper blade (100) of claim 1, wherein the support shell structure (110) completely surrounds one or more of the scraper elements (120a-c) in a direction (L1, L2) transverse to the scraper axis (A).

3. 3. The belt conveyor scraper blade (100) of claim 2, wherein the support shell structure (110) has a constant cross-sectional shape (P) along the scraper axis (A).

4. 4. The belt conveyor scraper blade (100) of claim 3, wherein the support shell structure (110) is manufactured by an extrusion process, an injection molding process, or a 3D printing process.

5. The belt conveyor scraper blade (100) of any one of claims 1 to 4, wherein the second material comprises polyurethane or a thermoplastic elastomer.

6. The belt conveyor scraper blade (100) according to any one of claims 1 to 5, wherein the first material is biodegradable and / or bio-based.

7. The belt conveyor scraper blade (100) of any one of claims 1 to 6, wherein the first material has a higher hardness than the second material.

8. The belt conveyor scraper blade (100) of any one of claims 1 to 7, wherein the first material comprises one or more from the list of thermoplastic elastomer, polyvinyl chloride, acrylonitrile styrene acrylate, and polyethylene.

9. The interior of the support shell structure (110) comprises a plurality of sections (133a-f) each defining a respective interior volume (132a-f), the plurality of sections (133a-f) comprising: one or more scraper sections (133a-c), each filled with a respective one of said one or more scraper elements (120a-c); one or more hollow sections (133d-f); The belt conveyor scraper blade (100) of any one of claims 1 to 8, comprising:

10. 10. The belt conveyor scraper blade (100) of claim 9, wherein the one or more hollow portions (133d-f) comprise a first hollow portion (133f) located within the mounting base (114).

11. The belt conveyor scraper blade (100) according to claim 9 or 10, wherein the one or more hollow portions (133d-f) comprise a second hollow portion (133d, 133e) located between the mounting base (114) and one or more of the scraper portions (132a-c).

12. 12. The belt conveyor scraper blade (100) according to any one of claims 9 to 11, wherein adjacent ones of the plurality of portions (133a-f) are separated from one another by separating structures (140a-e) interconnecting opposing walls (116a, 116b) of the supporting shell structure (110).

13. A belt conveyor scraper assembly (10) for scraping material from a belt conveyor surface (24), comprising: A plurality of belt conveyor scraper blades (100) according to any one of claims 1 to 12; a support shaft (26) structured and configured to support a plurality of said belt conveyor scraper blades (100); tensioning means (34) configured to apply a torque or force on the support shaft (26) to urge the plurality of belt conveyor scraper blades (100) against the belt conveyor surface (24); A belt conveyor scraper assembly (10) comprising:

14. 1. A method of manufacturing a belt conveyor scraper blade, comprising: a) manufacturing (S502) a support shell structure (110) made of a first material, the support shell structure (110) having a scraper tip (112) at a first end (111) and a mounting base (114) at an opposite second end (113), the support shell structure tapering at least at said first end (111) towards said scraper tip (112); b) placing (S504) one or more scraper elements (120a-c) made of a second material within the support shell structure (110) to at least partially fill the interior of the support shell structure (110) at the first end (111); A method comprising:

15. The method of claim 14, wherein the step (S502) of manufacturing the support shell structure (110) is accomplished by an extrusion process, an injection molding process, or a 3D printing process.

16. The step (S504) of disposing one or more of the scraper elements (120a-c) within the support shell structure (110) comprises: dispensing said second material in liquid form into said support shell structure (110) to at least partially fill the interior of said support shell structure (110) at said first end (111); 16. The method of claim 14 or 15, comprising: whereby the second material bonds with the first material of the support shell structure (110) to form a coherent structure during cooling.

17. The method of any one of claims 14 to 16, wherein the first and second materials are different.

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