Conveyor belt scraper blade and manufacturing method thereof

Abstract

The present disclosure relates to a conveyor belt scraper blade (100), comprising a support structure (110) comprising a base portion (170) and an engagement portion (150), wherein the engagement portion (150) interconnects with the base portion (170) and extends from the base portion toward a first end (111) of the scraper blade (100), wherein the engagement portion (150) comprises at least one reinforcing portion (151a-d), wherein the scraper element (111) is supported by a support structure (110). The scraper element (120) and the support structure (110) are attached to each other along the engagement portion (150) such that at least one reinforcing portion (151a-d) protrudes into the scraper element (120) and thereby reinforces the attachment between the scraper element (120) and the support structure (110), wherein the support structure (110) is made of a first material and the scraper element (120) is made of a second material, wherein the first material and the second material are different.

Description

[Technical Field]

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

[0002] Scraper blades for conveyor belts are used to clean conveyor belts from materials that adhere to and remain on the conveyor belt after the conveyed material leaves the belt. 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. It must also have good wear characteristics to reduce downtime due to scraper replacement. Replacing scraper blades too frequently is both economical and environmentally problematic due to the waste of resources. When a scraper blade for a conveyor belt is in operation, it gradually wears out as a result of the frictional forces exerted on it by the moving conveyor belt. At the end of its useful life, most of the scraper blade has been removed by wear, allowing time for replacement to maintain the required conveyor belt cleaning. After replacement, the remaining scraper blade must be discarded. A problem with prior art scraper blades is that once they reach the end of their useful life, their remaining parts constitute a significant amount of waste. Therefore, there is a need in the art for an improved scraper blade that reduces the amount of waste during replacement. Summary of the Invention

[0003] It is an object of the present invention 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 at least partly met 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 conveyor belt scraper blade having an extension along a scraper axis and configured to scrape material from a conveyor belt surface along a scraping area extending parallel to the scraper axis, the conveyor belt scraper blade having a scraper tip at a first end and a mounting base at a second, opposite end, the conveyor belt scraper blade tapering at least at the first end towards the scraper tip; Conveyor Belt Scraper Blades a support structure comprising a base portion and an engagement portion, wherein the base portion includes a mounting base, wherein the engagement portion interconnects with the base portion and extends from the base portion toward a first end, wherein the engagement portion comprises at least one reinforcing portion; a scraper element; wherein the scraper element and the support structure are attached to one another along the engagement portion such that at least one reinforcing portion protrudes into the scraper element, thereby reinforcing the attachment between the scraper element and the support structure; wherein the conveyor belt scraper blade is constructed and arranged to wear during use, and the scraper element is arranged relative to the support structure such that the scraper element wears completely or partially at the end of the useful life of the conveyor belt scraper blade; Here, the support structure is made of a first material and the scraper element is made of a second material, where the first material and the second material are different.

[0005] A conveyor belt scraper blade can be advantageous because its support structure allows for the selection of the portion of the conveyor belt scraper blade in which the scraper element should be accommodated. By selectively shaping and positioning the scraper element in a position that will wear out by the end of the conveyor belt scraper blade's useful life, the total amount of material required to manufacture the conveyor belt scraper blade is reduced, allowing a larger portion of the conveyor belt scraper blade to be used before the remaining portion is disposed of as waste. The use of two different materials also allows for the material properties to be selected independently of each other. This allows for a support structure with preferred properties to contribute to one function of the conveyor belt scraper blade, while scraper elements with other properties contribute to another function.

[0006] One purpose of the support structure is to help define the shape of the conveyor belt scraper blade. Another purpose of the support structure is to provide structural support and integrity to the conveyor belt scraper blade. An advantage of the conveyor belt scraper blade is that its two different materials allow for minimizing the amount of material used to maintain the structural shape of the conveyor belt scraper blade. This can minimize both the amount of material used for the support structure and the amount of material used for the scraper element. As a result, the conveyor belt scraper blade has a smaller environmental footprint and can be more economically beneficial.

[0007] During use, a conveyor belt scraper blade is subject to wear at the contact point between the scraper blade and the conveyor belt. Wear occurs at the location of the scraper that contacts the conveyor belt. Therefore, a newly replaced conveyor belt scraper blade may initially be subject to wear of only the scraper element. However, after a while, wear may increase to a level where the engaging portion of the support structure also contacts the conveyor belt. Therefore, the scraper element may be subject to wear both alone and together with the support structure. At the end of the useful life of a conveyor belt scraper blade, the scraper element is completely or partially worn. Therefore, when a conveyor belt scraper blade is replaced, the waste material mainly or exclusively comprises the remaining portion of the support structure. Because the remaining portion of the support structure is not intended to perform any scraping, the remaining portion of the support structure may be structured and arranged to provide only structural integrity, which allows for a design with a reduced amount of material compared to scrapers in the art.

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

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

[0010] The term "engagement portion" herein should be interpreted as a portion of the support structure that engages with the scraper element. This means that the engagement portion has an engagement surface to which the scraper element is attached. The engagement surface may have at least one engagement surface portion extending from the base portion toward the first end. The engagement surface may have at least one engagement surface portion extending along the intersection between the base portion and the engagement portion. Each reinforcing portion of the one or more reinforcing portions may protrude outward from any one of the engagement surface portions of the engagement portion. As will be readily understood by those skilled in the art, the above means that the scraper element is located closer to the first end than the base. The engagement portion may extend from the base portion to the first end, thereby connecting the base portion with the first end. In such an exemplary embodiment, the support structure includes a scraper tip. However, it is conceivable that the engagement portion extends only from the base toward the first end, and not all the way to the first end. In such an exemplary embodiment, the scraper element includes a scraper tip.

[0011] According to some embodiments, the engagement portion protrudes into the scraper element such that the scraper element partially surrounds the engagement portion from the base toward the first end in a direction transverse to the scraper axis. This means that the scraper element is attached to the support structure on more than one side of the support structure. In other embodiments, the scraper element may be attached to only one side of the support structure. The fact that the engagement portion interconnects with the base and extends from the base toward the first end means that the engagement portion may have an engagement surface that, in use, has one engagement surface portion facing away from the conveyor belt and one engagement surface portion facing the conveyor belt. In embodiments in which the engagement portion protrudes into the scraper element and the scraper element partially surrounds the engagement portion from the base toward the first end in a direction transverse to the scraper axis, the engagement portion may be attached to the scraper element along both of these two engagement surface portions.

[0012] The direction transverse to the scraper axis includes a first direction extending from the first end to the second end of the conveyor belt scraper blade and a second direction perpendicular to the first direction and the scraper axis, and thus generally extending along the direction of conveyor belt movement when the conveyor belt scraper blade is in use.

[0013] An advantage of providing a protruding engagement portion within the scraper element such that the scraper element partially surrounds the engagement portion from the base toward the first end transversely to the scraper axis is that the scraper blade may be easier to manufacture. Another advantage is that the scraper blade may have greater structural integrity. Yet another advantage is that the scraper blade may be easier to recycle.

[0014] It is emphasized that the above does not mean that the scraper element surrounds the engagement portion in all three dimensions: the scraper element may also be structured in such a way that it does not surround the engagement portion along the scraper axis.

[0015] According to some embodiments, the support structure has a constant cross-sectional profile along the scraper axis.

[0016] According to some embodiments, the support structure is manufactured at least in part by an extrusion process, an injection molding process, or a 3D printing process.

[0017] The extrusion process is a reliable process for producing support structures with a consistent cross-sectional profile. 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 makes it possible to produce long conveyor belt scraper blades so that a single scraper blade can cover the entire scraping width. The injection molding process is also considered a reliable process for producing support structures. It is a versatile technique and allows for the production of highly complex shapes. Specifically, it allows for the production of support structures with cross-sectional profiles that vary along the scraper axis. The 3D printing process is also considered a reliable process for producing support structures. While the production time may not be as fast, it allows for the production of highly complex shapes. Furthermore, design changes are more easily implemented because there is no need to design and manufacture specialized elements, such as the tailored molds used in extrusion and injection molding processes.

[0018] According to some embodiments, the second material comprises a polymer.

[0019] According to some embodiments, the second material comprises polyurethane or a thermoplastic elastomer.

[0020] 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 advantage of using thermoplastic elastomers is 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 can be that, while most elastomers are thermosets, thermoplastic elastomers 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-based block copolymers (TPE-s), CAWITON®, THERMOLAST® K, THERMOLAST® M, Sofprene, Dryflex, and Laprene are listed. Examples of thermoplastic polyurethanes (TPUs) are Laripur®, Desmopan® or Elastollan®. 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.

[0021] The second material may also comprise other types of materials suitable for scrubbing a conveyor belt, such as rubber.

[0022] It is also contemplated that additional compounds may be blended into the material. As an example, carbides may be suitable for some embodiments of conveyor belt scraper blades due to their high wear resistance. In other words, the scraper element may be made from a material including, for example, carbide powder. The carbide powder may be mixed with a polymer material such as polyurethane. It is also contemplated to provide scraper elements including other ceramic powders or graphene powder.

[0023] According to some embodiments, the first material is biodegradable and / or bio-based. Providing a biodegradable and / or bio-based first material can further reduce 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 elements and composted. Therefore, providing these materials can completely eliminate or at least reduce landfill growth.

[0024] According to 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 50-95° Shore A, typically more preferably 70° Shore A. When the first material is harder than the second material, the support structure can provide the stability necessary for the conveyor belt scraper blade to maintain its shape during use.

[0025] The increased stability of the support 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 wear-resistant, increasing the lifespan of conveyor belt scraper blades. The benefit of this increased lifespan is that conveyor belt scraper blades do not need to be replaced as frequently, reducing the need for conveyor belt maintenance.

[0026] According to some embodiments, the first material comprises a polymer.

[0027] According to some embodiments, the first material comprises one or more from the list of thermoplastic elastomer, polyvinyl chloride, acrylonitrile styrene acrylate, and polyethylene.

[0028] The first material can be a thermoplastic polymer. One suitable thermoplastic polymer is 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.

[0029] 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 also be selected from other compounds.

[0030] 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 each comprise a polyurethane. The difference between the first and second materials in this case depends on the composition, and the other compound parts of the composition may be different.

[0031] 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.

[0032] According to some embodiments, each of the one or more reinforcing portions has a proximal end connected to the engagement portion and a distal end disposed opposite the proximal end, wherein the distal end includes a fixing portion having a thickness greater than that of the reinforcing portion, the thickness being defined in a plane transverse to the scraper axis. The fixing portion can be advantageous because it helps secure the scraper element to the support structure through a locking engagement. This further helps hold the scraper blade together, thus increasing the structural integrity and durability of the scraper blade.

[0033] According to some embodiments, the fastening portion comprises two sub-portions projecting in different directions from the distal end. The angle between the two sub-portions may be in the range of 20 to 180 degrees, preferably 70 to 110 degrees. The two sub-portions may extend outward away from the engaging portion. Alternatively, the two sub-portions may extend inward toward the engaging portion. It is also conceivable to have only one sub-portion. In this case, the sub-portion may project in a different direction from the distal end of the reinforcing portion.

[0034] The fixing part may be embodied in many alternative ways, for example with a circular or square cross section. As long as the thickness of the reinforcing part is greater than the thickness of the fixing part, the locking engagement is achieved.

[0035] According to some embodiments, the support structure comprises one or more hollow sections, each defining a respective interior volume. The one or more hollow sections may be advantageous because they further reduce the overall volume of the conveyor belt scraper blade, thereby reducing the volume of waste when a worn conveyor belt scraper blade is disposed of at the end of its useful life. Another advantage of the hollow sections may be that they make the conveyor belt scraper blade easier to handle due to its lighter weight.

[0036] Each of the one or more hollow portions may be a through opening extending through the support structure along the scraper axis.

[0037] According to some embodiments, the one or more hollow portions are located within the base portion.

[0038] According to some embodiments, the one or more hollow portions include a first hollow portion located within the mounting base. The first hollow portion may be used to mount a conveyor belt scraper blade. The first hollow portion may also be used as a mounting means for mounting a conveyor belt scraper blade.

[0039] According to some embodiments, the one or more hollow portions include a second hollow portion located between the mounting base and the scraper portion, which can contribute to more efficient use of material.

[0040] According to some embodiments, the support structure (110) comprises one or more through-holes extending through the engagement portion. Each of the one or more through-holes may extend in a direction transverse to the scraper axis. The one or more through-holes may be advantageous because they allow a second material comprising the scraper element to extend through the through-hole, thus further strengthening the structural integrity of the scraper blade. The one or more through-holes may extend through any portion of the engagement portion. For example, the one or more through-holes may extend through one or more reinforcing portions. The one or more through-holes may extend through the engagement portion in a direction transverse to the scraper axis.

[0041] According to a second aspect, there is provided a conveyor belt scraper assembly for scraping material from a conveyor belt surface, the conveyor belt scraper assembly comprising: a plurality of conveyor belt scraper blades according to a first aspect; a support shaft structured and arranged to support a plurality of conveyor belt scraper blades; and tensioning means configured to exert a torque or force on the support shaft to urge the plurality of conveyor belt scraper blades against the conveyor belt surface.

[0042] According to a third aspect, there is provided a method of manufacturing a conveyor belt scraper blade having a scraper tip at a first end and a mounting base at a second, opposite end, the scraper blade tapering at least at the first end towards the scraper tip, the method comprising: a) manufacturing a support structure made of a first material, wherein the support structure comprises a base portion and an engagement portion, wherein the base portion includes a mounting base, wherein the engagement portion interconnects with the base portion and extends from the base portion toward a first end, wherein the engagement portion comprises at least one reinforcing portion; b) placing the scraper element made of the second material on the support structure so that the scraper element and the support structure are attached to each other along the engagement portion and so that at least one reinforcing portion protrudes into the scraper element, thereby reinforcing the attachment between the scraper element and the support structure.

[0043] According to some embodiments, the step of manufacturing the support structure is accomplished at least in part by an extrusion process, an injection molding process, or a 3D printing process. When an embodiment of the support structure having one or more through holes is manufactured at least in part by an extrusion process, a support structure without through holes may be first manufactured by the extrusion process, and in a second step, one or more through holes may be provided therein, for example by drilling.

[0044] According to some embodiments, the step of placing the scraper element on the support structure comprises: placing a support structure within the mold; and dispensing a second material in liquid form into the mold such that the second material contacts the support structure along the engagement portion; The second material thereby bonds with the first material of the support structure to form a coherent structure during cooling.

[0045] According to some embodiments of the method, the first material and the second material are different.

[0046] The support structure may 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 structure. As an example, the support structure may be manufactured via an extrusion process by manufacturing two or more separate sections that are then attached to each other. This modular manufacturing process may be beneficial for longer conveyor belt scraper blades, for example, which may be difficult to manufacture using an extrusion process. 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 structure before the modules are attached together.

[0047] 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 generally 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.

[0048] Further scope of applicability of the present disclosure will become apparent from the detailed description given hereinafter. It should be understood, however, that the detailed description and specific examples, while indicating preferred versions of the invention, are given by way of illustration only, since various changes and modifications within the scope of the present disclosure will become apparent to those skilled in the art from this detailed description.

[0049] Therefore, it should be understood that the disclosure is not limited to the particular component parts of the described devices or described method steps, as such devices and methods may vary. It should also 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 clearly dictates otherwise. Thus, for example, reference to "a unit" or "the unit" may include several devices, etc. Furthermore, the terms "comprising," "including," "containing," and similar terms do not exclude other elements or steps.

[0050] 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]

[0051] [Figure 1] FIG. 1 is a perspective view of a conveyor belt scraper assembly according to an exemplary embodiment of the present disclosure. [Figure 2A] FIG. 2A is a perspective view of a conveyor belt scraper blade according to an exemplary embodiment of the present disclosure. [Figure 2B] FIG. 2B is a perspective view of a support structure for the conveyor belt scraper blade of FIG. 2A. [Figure 3A] FIG. 3A is a cross-sectional view of the support structure for the conveyor belt scraper blade of FIGS. 2A and 2B. [Figure 3B] FIG. 3B is a cross-sectional view of a scraper element of the conveyor belt scraper blade of FIG. 3A. [Figure 3C] FIG. 3B is a cross-sectional view of the reinforcement of the conveyor belt scraper blade of FIG. 3A. [Figure 4A]FIG. 4A is a cross-sectional view of a support structure for a conveyor belt scraper blade according to an alternative exemplary embodiment. [Figure 4B] FIG. 4B is a cross-sectional view of a scraper element of the conveyor belt scraper blade of FIG. 4A. [Figure 4C] FIG. 4C is a perspective view of the support structure of FIG. 4A. [Figure 5] FIG. 5 is a flow chart illustrating different steps in a method for manufacturing a conveyor belt scraper blade according to the present disclosure. [Figure 6A] FIG. 6A is a schematic side view of the support structure of FIGS. 4A-C being inserted into a mold. [Figure 6B] FIG. 6B is a schematic side view of the support structure and mold of FIG. 6A immediately after the mold has been filled with a second material to become the scraper element of FIG. 4B. [Figure 6C] FIG. 6C is a schematic side view of the support structure and scraper element after the mold has been removed. DETAILED DESCRIPTION OF THE INVENTION

[0052] The present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, which show presently preferred embodiments of the invention. 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, so as to fully convey the scope of the disclosure to those skilled in the art.

[0053] Conveyor belts are used to transport large amounts of material from one location to another. In certain applications, for example in the mining industry, conveyor belts are used to transport materials such as sand, ore, gravel, coal, minerals, etc. In such applications, the materials tend to adhere to the conveyor belt surface, and therefore the conveyor belt surface needs to be cleaned.

[0054] One known solution for keeping conveyor belts clean is to mechanically remove material that has built up on the belt surface. An example of this type of cleaning system is illustrated in FIG. 1 in the form of a conveyor belt scraper assembly 10. The conveyor belt scraper assembly 10 includes a plurality of conveyor belt scraper blades 100 arranged adjacent to one another to form a common conveyor belt scraper structure of sufficient length to scrape the entire width, or at least a majority of the width, of the conveyor belt surface 24. The conveyor belt scraper assembly 10 includes a support shaft 26 constructed and arranged to support the plurality of conveyor belt scraper blades 100. The conveyor belt scraper blades 100 are more fully described in connection with FIGS. 2A and 2B. The support shaft 26 is configured to urge the plurality of conveyor belt scraper blades 100 toward the conveyor belt surface 24 via suitable tensioning means 34. The tensioning means 34 is configured to exert a torque or force on the support shaft 26 such that the support shaft 26 presses the conveyor belt scraper blade 100 toward the conveyor belt surface 24. As will be appreciated 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 conveyor belt surface 24 moves relative to the conveyor belt scraper blade 100, the scraper blade 100 scrapes adhered material from the conveyor belt surface 24. The conveyor belt scraper blade 100 is attached to a mounting element 28 that is rigidly fixed to a rectangular tube 27 attached to the support shaft 26. Thus, the mounting element 28 and the conveyor belt scraper blade 100 mounted thereon can be easily and quickly installed and removed as a single unit. Conveyor belt scraper blades 100 are mounted to support shafts 26 via respective mounting bases 114 (see, e.g., FIG. 2A ). Mounting bases 114 may be shaped to form a locking engagement with support shafts 26.The conveyor belt scraper blade 100 is intended to be positioned relative to the conveyor belt surface 26 so that its upper end 111 contacts the conveyor belt surface 26 along a scraping area 16 (see dotted line in FIG. 1 ). The scraping area 16 extends parallel to the extension of the conveyor belt scraper blade 100. The scraping area 16 also extends substantially parallel to the axis of rotation R of the conveyor belt pulley 25.

[0055] 2A-2B and 3A-3C illustrate a conveyor belt scraper blade 100 according to an exemplary embodiment. The conveyor belt scraper blade 100 extends along a scraper axis A and has a scraper tip 112 at a first end 111 and a mounting base 114 at an opposite second end 113. The conveyor belt scraper blade 100 tapers toward the scraper tip 112 at at least the first end 112. The conveyor belt scraper blade 100 comprises a support structure 110 and a scraper element 120 attached to one another. In the exemplary embodiment, the support structure 110 comprises the scraper tip 112, although in an alternative embodiment (not shown), the support structure comprises the scraper tip.

[0056] The support structure 110 includes a base portion 170 that includes a mounting base 114. The support structure 110 further includes an engagement portion 150 that interconnects with the base portion 170 and extends from the base portion toward the first end 111. As seen in FIG. 2A , the engagement portion 150 extends only partially from the base portion 170 to the first end 111. Instead, the scraper element 120 has a scraper tip 112, thereby defining the first end 111 of the scraper blade 100. The engagement portion 150 includes at least one reinforcing portion 151 a-d (in the exemplary embodiment, four reinforcing portions 151 a-d). In the exemplary embodiment, the four reinforcing portions 151 a-d are generally similar. By way of example, the engagement portion 151 d is shown in more detail in FIG. 3C and is described further below.

[0057] As seen in FIG. 2A , the scraper element 120 and the support structure 110 are attached to one another along an engagement portion 150 such that at least one reinforcing portion 151 a-d protrudes into the scraper element 120, thereby reinforcing the attachment between the scraper element 120 and the support structure 110. As best shown in FIG. 3C , each of the one or more reinforcing portions 151 a-d has a proximal end 152 connecting to the engagement portion 150 and a distal end 153 disposed opposite the proximal end 152, wherein the distal end 153 includes a fastening portion 154 having a thickness W2 greater than the thickness W1 of the reinforcing portions 151 a-d, the thicknesses W1 and W2 being defined in a plane transverse to the scraper axis A. The purpose of the fastening portion 154 is to help secure the scraper element 120 to the support structure 110 by locking engagement. In the exemplary embodiment, the securing portion 154 includes two sub-portions 154a, 154b that protrude in different directions at the distal end 153. These directions are illustrated by dotted lines in FIG. 3C. The angle between the two sub-portions 154a, 154b may be within a range of 30 to 120 degrees, preferably within a range of 60 to 100 degrees. In the exemplary embodiment, the angle is 90 degrees. As illustrated in FIG. 3C, the two sub-portions 154a, 154b extend outward away from the engaging portion 150. In other exemplary embodiments (not shown), the two sub-portions may extend inward toward the engaging portion. In still other embodiments (not shown), there is only one sub-portion that protrudes from the distal end in a direction different from the direction of the reinforcing portion. As will be readily understood by those skilled in the art, the securing portion 154 may be embodied in many alternative ways, such as having a circular or square cross-section. As long as the thickness W2 is greater than the thickness W1, locking engagement is achieved.

[0058] As best shown in Figure 2B, the support structure of conveyor belt scraper blade 100 has a constant cross-sectional profile along scraper axis A. This provides particular advantages for manufacturing conveyor belt scraper blade 100, as will be described in more detail below.

[0059] The engagement portion 150 is defined herein as the portion of the support structure 110 that engages with the scraper element 120. As seen in FIGS. 2A and 2B , the engagement portion 150 extends from the base portion 170 toward the first end 111. The engagement portion 150 further extends outward at the bottom of the engagement portion 150 to support the scraper element 120 from below. This means that the engagement portion 150 has two engagement surface portions: an engagement surface portion 115a that intersects with the engagement surface portion 125a of the scraper element 120, and an engagement surface portion 115b that intersects with the engagement surface portion 125b of the scraper element 120. The engagement surface portion 115a extends from the base portion 170 toward the first end 111, and the engagement surface portion 115b extends along the intersection between the base portion 170 and the engagement portion 150. Engagement surfaces 115a-b, 125a-b are most clearly illustrated in Figures 3A and 3B, respectively.

[0060] The support structure 110 includes one or more hollow portions 133a-c, each defining a respective interior volume 132a-c (see FIGS. 2A and 2B). The one or more hollow portions 133a-c in the exemplary embodiment are located within the base portion 170 and include three hollow portions 133a-c. Alternative embodiments may have other numbers of hollow portions 133a-c or no hollow portions 133a-c. One or more hollow portions 133a-c may be through-openings extending through the support structure 110 along the scraper axis A. The one or more hollow portions 133a-c are separated from one another by a separating structure 140 that interconnects opposing walls 116a, 116b of the base portion 170. The separating structure 140 may be a wall that completely separates adjacent hollow portions 133a-c from one another. The separation structure 140 is connected at each end to one of the opposing walls 116a, 116b. In this exemplary embodiment, the opposing walls 116a, 116b are defined as walls extending from the mounting base 114 toward the first end 111. In other embodiments, the separation structure 140 may extend between other walls of the support structure 110. The use of one or more hollow portions 133a-c allows for many different designs of the conveyor belt scraper blade 100. It is also possible to adapt the conveyor belt scraper blade 100 to different conveyor belt scraper assemblies 10. The hollow portions 133a-c reduce the weight of the conveyor belt scraper blade 100, making it easier to handle. An additional advantage of the separation structure 140 is that it provides a clear separation of the portions, which facilitates the manufacture of conveyor belt scraper blades with desired shapes and characteristics. 2A consists of a first hollow portion 133c located within mounting base 114 and two hollow portions 133a, 133b located on top of base portion 170 between mounting base 114 and scraper element 120. To reduce the amount of waste generated when replacing worn conveyor belt scraper blades, scraper element 120 preferably encloses only the portion of the scraper blade that will wear during use.Thus, as will be readily understood by one skilled in the art, the slope of each isolation structure 140, their number, as well as the number of hollow portions 133a-c can be design parameters.

[0061] The scraper element 120 may have multiple fins 160 on one of the 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 conveyor belt scraper blade 100.

[0062] 4A-4C, an alternative embodiment of a conveyor belt scraper blade is disclosed, namely, conveyor belt scraper blade 200. As will be readily understood by one of ordinary skill in the art upon viewing the figures, this alternative embodiment shares several features with conveyor belt scraper blade 100 described hereinabove. For clarity, features in common with the first embodiment are assigned the same reference numerals, and features unique to the second exemplary embodiment are assigned higher reference numerals.

[0063] The conveyor belt scraper blade 200 differs from the conveyor belt scraper blade 100 in that the engagement portion 250 protrudes into the scraper element 220 in a direction L1, L2 transverse to the scraper axis A, from the base portion 170 toward the first end 111, so that the scraper element 220 partially surrounds the engagement portion 250. As seen in FIGS. 4A and 4B , the support structure 210 contacts the scraper element 220 on two or more sides. The engagement portion 250 has engagement surfaces 215 a-c that can be divided into three separate engagement surface portions. As with the first exemplary embodiment, the engagement surface portion 215 b extends along the intersection between the base portion 170 and the engagement portion 250. The other two engagement surface portions 215a, 215c are defined on a portion of the engagement portion 250 extending toward the first end 111, including the engagement surface portion 215a facing away from the conveyor belt in use and the engagement surface portion 215c facing toward the conveyor belt (the conveyor belt is located to the left of the scraper blade 200 in FIG. 4A ). In other words, the engagement portion 250 is attached to the scraper element 220 on two opposite sides of the engagement portion 250. An advantage of providing the engagement portion 250 protruding into the scraper element 220 so that the scraper element 220 partially surrounds the engagement portion 250 from the base 170 toward the first end 111 in a direction transverse to the scraper axis A is that the scraper blade 200 can be manufactured more easily. Another advantage is that the scraper blade 200 can have higher structural integrity.

[0064] As previously mentioned, the engagement portion 250 is defined herein as the portion of the support structure 210 that engages with the scraper element 220. As seen in FIGS. 4B and 4C , the engagement portion 250 extends from the base portion toward the first end 111. The engagement portion 250 further extends outward at the bottom of the engagement portion 250 to contact the scraper element 220 from below. In this respect, the support structure 210 is similar to the support structure 110. However, the engagement surfaces differ between embodiments. The engagement portion 250 has an engagement surface portion 215a and an engagement surface portion 250c located on either side of the engagement portion 215. Thus, the scraper element 220 has complementary engagement surface portions 225a, 225c, which are defined as the inner surfaces of the cavity 228, as shown in FIG. 4B . Finally, the scraper element 220 has an engagement surface portion 225b attached to the engagement surface portion 215b of the support structure 210.

[0065] As also seen in FIGS. 4B and 4C , the support structure 210 includes one or more through-holes 260, 261 extending through the engagement portion 250. The through-holes 260, 261 extend through the engagement portion 250 in a direction transverse to the scraper axis A. The through-hole 260 interconnects the engagement surface portion 215a with the engagement surface portion 215c. In the exemplary embodiment, there are four such through-holes 260. The through-holes may alternatively extend through one or more of the reinforcing portions. This is illustrated in FIG. 4C for the exemplary embodiment, where the through-hole 261 extends through the reinforcing portion 251d. However, through-holes may also be provided in the other reinforcing portions 151a-c. The through-holes 260, 261 may be advantageous because they allow the second material comprising the scraper element 220 to extend through the through-holes, thus further enhancing the structural integrity of the scraper blade 200. Although illustrated herein only with respect to the second exemplary embodiment, the through holes 260, 261 may also be used with the first exemplary embodiment or any other embodiment falling within the scope of the appended claims.

[0066] The material properties of the conveyor belt scraper blade of the present disclosure will now be described in detail. This will be done with reference to the first exemplary embodiment, conveyor belt scraper blade 100, but the description is equally valid for other exemplary embodiments described herein and within the scope of the claims. When designing the conveyor belt scraper blade 101, an important factor is the material. The support structure 110 is made from a first material, and the scraper elements 120 are made from a second material. The first and second materials are different. The use of two different materials allows the material properties to be selected independently of each other. This may make it possible to provide a support structure 110 with one preferred property that contributes to one function of the conveyor belt scraper blade 100 and a scraper element 120 with another property that contributes to another function.

[0067] The purpose of the support structure 110 is to provide structural integrity to the conveyor belt scraper blade 100. An advantage of the support structure 110 is that it allows for minimizing the amount of material required to maintain the structural shape of the conveyor belt scraper blade 100. This can minimize both the amount of material used for the support structure 110 and the amount of material used for the scraper elements 120. The first material from which the support structure 110 is made may be biodegradable and / or bio-based. Providing a biodegradable and / or bio-based first material further reduces environmental impact. When worn out, the remaining portion of the scraper 100 can be disposed of sustainably. For example, it may be shredded into smaller elements and composted. Therefore, providing these materials can completely eliminate or at least reduce landfill growth. The first material can include one or more from the following list: thermoplastic elastomer, polyvinyl chloride, acrylonitrile styrene acrylate, and polyethylene. The first material can be a thermoplastic polymer. One suitable thermoplastic polymer may 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.

[0068] 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 also be selected from other compounds.

[0069] The purpose of the scraping element 120 is to perform a scraping action on the conveyor belt surface 26. Important properties of the scraping element 120 may be wear resistance and flexibility to reduce the risk of the scraper element 120 damaging the conveyor belt surface 24. The second material from which the scraper element 120 is made may comprise a polymer, such as polyurethane or a thermoplastic elastomer. The second material may alternatively comprise a carbide material, for example, in the form of a carbide powder mixed into an additional material, such as a polymeric material. Polyurethane may provide 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. An advantage of using a thermoplastic elastomer is its ability to stretch to a moderate elongation and return to its approximate 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 may be thermoplastic polyurethane (TPU). Carbonized materials may be suitable for some embodiments of conveyor belt scraper blades due to their high abrasion resistance. The second material may also include other types of materials suitable for scraping conveyor belts, such as rubber.

[0070] 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 structure can provide the stability necessary for the conveyor belt scraper blade to maintain its shape during use.

[0071] The support structure of the conveyor belt scraper blade of the present disclosure can be manufactured, at least in part, by an extrusion process. Extrusion processes are 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 profile. Such a product may be the support structure and / or scraper element of the present disclosure. Using an extrusion process, the support structure can be easily manufactured, which is advantageous from an economic standpoint.

[0072] A method of manufacturing a conveyor belt scraper blade is described with reference to Figure 5. The method is equally applicable to both the exemplary embodiment of the present disclosure and any other embodiment falling within the scope of the appended claims. The scraper blade 100, 200 has a scraper tip 112 at a first end 111, a mounting base 114 at an opposite second end 113, and is tapered toward the scraper tip 112 at at least the first end 111. The method comprises the following steps: a) step S502 of manufacturing a support structure 110, 210 made of a first material, wherein the support structure 110, 210 comprises a base portion 170 and an engagement portion 150, 250, wherein the base portion 170 includes a mounting base 114, wherein the engagement portion 150, 250 interconnects with the base portion 170 and extends from the base portion 170 towards the first end 111, wherein the engagement portion 150, 250 comprises at least one reinforcing portion 151a-d; 251d; b) Step S504 of placing the scraper element 120, 220 made of the second material on the support structure 110, 210 so that the scraper element 120, 220 and the support structure 110, 210 are attached to each other along the engagement portion 150, 250 and so that at least one reinforcing portion 151a-d; 251d protrudes into the scraper element 120, 220, thereby reinforcing the attachment between the scraper element 120, 220 and the support structure 110, 210.

[0073] Step S502 of manufacturing the support structure 110, 210 may be accomplished, at least in part, by an extrusion process, an injection molding process, or a 3D printing process.

[0074] Step S504 of placing the scraper elements 120, 220 on the support structure 110, 210 can include placing the support structure 110, 210 in a mold M, as illustrated in FIG. 6A for the second exemplary embodiment. A second material may then be dispensed into the mold M in liquid form so that the second material contacts the support structure 210 along the engagement portion 250. The dispensing of material is indicated by the arrows in FIG. 6A. FIG. 6B illustrates a fully filled mold M. Once filled, the second material combines with the first material of the support structure 210 to form a coherent structure during cooling. The mold M can then be removed. As will be readily understood by those skilled in the art, the process is similar to the first exemplary embodiment; the mold must be somewhat smaller, and the liquid second material is filled from the opposite end of the mold.

[0075] As mentioned above, the first and second materials are different. However, this does not exclude that both the first and second materials can contain the same compound, such as polyethylene. The first and second materials can each be a respective composition of two or more compounds, one of which is common to both materials.

[0076] The figures of the present disclosure illustrate the conveyor belt scraper blades 100, 200 before use. However, the conveyor belt scraper blades 100, 200 are configured and arranged to wear during use, and the scraper elements 120, 220 are positioned relative to the support structure 110, 210 so that the scraper elements 120, 220 will wear completely or partially at the end of the useful life of the conveyor belt scraper blades 100, 200. During use, the conveyor belt scraper blades 100, 200 experience wear at the points of contact between the conveyor belt scraper blades 100, 200 and the conveyor belt surface 24. Wear occurs at the location of the conveyor belt scraper blade 100, 200 that contacts the conveyor belt surface 24, i.e., the scraping area 16. Thus, a newly replaced conveyor belt scraper blade 100, 200 first experiences wear of the scraper elements 120, 220. As the tops of the scraper elements 120, 220 wear and the conveyor belt surface 24 reaches the top of the support structures 110, 210, the support structures 110, 210 gradually wear as well. Thus, the scraper elements 120, 220 may experience wear both alone and together with the support structures 110, 210. At the end of the useful life of the conveyor belt scraper blade 100, 200, the scraper elements 120, 220 are completely or partially worn. Thus, when replacing the conveyor belt scraper blade 100, 200, the waste material mainly or only comprises the remaining portions of the support structures 110, 210. Therefore, the appearance of a used conveyor belt scraper blade 100, 200 can be very different from the appearance of a new conveyor belt scraper blade 100, 200, as shown in the figures.

[0077] Those skilled in the art will understand 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 conveyor belt scraper blade (100) having an extension along a scraper axis (A) and configured to scrape material from the conveyor belt surface (24) along a scraping region (16) extending parallel to the scraper axis (A), wherein the conveyor belt scraper blade (100) has a scraper tip (112) at a first end (111) and a mounting base (114) at a second end (113) on the opposite side, and is tapered at least at the first end (111) toward the scraper tip (112), The conveyor belt scraper blade (100) is A support structure (110) comprising a base portion (170) and an engaging portion (150), wherein the base portion (170) includes the mounting base (114), and the engaging portion (150) is interconnected with the base portion (170) and extends from the base portion toward the first end (111), and the engaging portion (150) comprises at least one reinforcing portion (151a-d), It comprises a scraper element (120), Herein, the scraper element (120) and the support structure (110) are attached to each other along the engaging portion (150) such that at least one reinforcing portion (151a-d) protrudes into the scraper element (120), thereby reinforcing the attachment between the scraper element (120) and the support structure (110). Herein, the conveyor belt scraper blade (100) is configured and positioned to wear during use, and the scraper element (120) is positioned relative to the support structure (110) such that the scraper element (120) is completely or partially worn at the end of the service life of the conveyor belt scraper blade (100). Herein, the support structure (110) is made of a first material, and the scraper element (120) is made of a second material, wherein the first material and the second material are different, conveyor belt scraper blade (100).

2. The conveyor belt scraper blade (200) according to claim 1, wherein the engaging portion (250) protrudes into the scraper element (220) such that the scraper element (220) partially surrounds the engaging portion (250) from the base (170) toward the first end (111) in a direction (L1, L2) that the scraper axis (A) is crossed by the conveyor belt scraper blade (200).

3. The conveyor belt scraper blade (100) according to claim 1, wherein the support structure (110) has a constant cross-sectional profile (P) along the scraper axis (A).

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

5. The conveyor belt scraper blade (100) according to claim 1, wherein the second material comprises polyurethane or thermoplastic elastomer.

6. The conveyor belt scraper blade (100) according to claim 1, wherein the first material is biodegradable and / or of biological origin.

7. The conveyor belt scraper blade (100) according to claim 1, wherein the first material has a higher hardness than the second material.

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

9. Each of the one or more reinforcing portions (151a-d) has a proximal end (152) connected to the engaging portion (150) and a distal end (153) located on the opposite side of the proximal end (152), wherein the distal end (153) is provided with a fixing portion (154) having a thickness (W2) greater than the thickness (W1) of the reinforcing portion (151a-d), and the thicknesses (W1, W2) are defined in a plane that crosses the scraper axis (A), as described in claim 1, for the conveyor belt scraper blade (100).

10. The conveyor belt scraper blade (100) according to claim 9, wherein the fixing portion comprises two sub-parts (154a, 154b) protruding in different directions from the distal end (153).

11. The conveyor belt scraper blade (100) according to claim 1, wherein the support structure (110) comprises one or more hollow portions (133a-c) each defining an internal volume (132a-c).

12. The conveyor belt scraper blade (100) according to claim 11, wherein one of the one or more hollow portions (133a-c) is located within the base portion (170).

13. The conveyor belt scraper blade (100) according to claim 11, wherein the one or more hollow portions (133a-c) are a plurality of hollow portions (133a-c).

14. The conveyor belt scraper blade (100) according to claim 11, wherein each of the one or more hollow portions (133a-c) is a through opening that extends along the scraper axis (A) through the support structure (110).

15. The conveyor belt scraper blade (200) according to claim 1, wherein the support structure (210) is provided with one or more through holes (260, 261) extending through the engaging portion (250).

16. A conveyor belt scraper assembly (10) for scraping material off the surface (24) of a conveyor belt, A plurality of conveyor belt scraper blades (100) according to any one of claims 1 to 15, A support shaft (26) is structured and arranged to support the plurality of conveyor belt scraper blades (100), A conveyor belt scraper assembly (10) comprising a tensioning means (34) configured to apply torque or force to the support shaft (26) in order to press the plurality of conveyor belt scraper blades (100) toward the conveyor belt surface (24).

17. A method for manufacturing a conveyor belt scraper blade (100, 200) having a scraper tip (112) at a first end (111) and a mounting base (114) at a second end (113) on the opposite side, and tapering toward the scraper tip (112) at least at the first end (111), wherein The aforementioned method, a) A step (S502) of manufacturing a support structure (110, 210) made of a first material, wherein the support structure (110, 210) comprises a base portion (170) and an engaging portion (150), wherein the base portion (170) includes the mounting base (114), wherein the engaging portion (150) is interconnected with the base portion (170) and extends from the base portion toward the first end (111), wherein the engaging portion (150) comprises at least one reinforcing portion (151a-d), b) A method comprising the step (S504) of positioning scraper elements (120, 220) made of a second material onto the support structure (110, 210) such that the scraper elements (120, 220) and the support structure (110, 210) are mounted to each other along the engagement portion (150, 250), and the at least one reinforcing portion (151a-d) protrudes into the scraper elements (120, 220), thereby reinforcing the mounting between the scraper elements (120, 220) and the support structure (110, 210).

18. The method according to claim 17, wherein the step (S502) of manufacturing the support structure (110) is achieved at least in part by an extrusion process, an injection molding process, or a 3D printing process.

19. The step (S504) of placing the scraper elements (120, 220) on the support structure (110, 210) is, The support structure (110, 210) is placed inside the mold (M), The method comprises supplying the second material in liquid form into the mold (M) such that the second material contacts the support structure (110, 210) along the engaging portions (150, 250), The method according to claim 17, wherein the second material is bonded to the first material of the support structure (110, 210) so as to form a coherent structure during cooling.

20. The method according to any one of claims 17 to 19, wherein the first material and the second material are different.

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