Flexible Elastomeric Liner Panels for Hopper Flow Blockages

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Solution Overview

Problem

Bulk materials, especially those containing moisture, tend to stick in hoppers and chutes, causing flow blockages and wear to equipment, leading to downtime and maintenance costs.

Innovation Solution

A flexible liner system with elastomeric panels or tiles featuring flexible fins or flaps that extend at an acute angle to facilitate material flow, using the energy of the materials to prevent sticking and act as a replaceable wear liner, with various mounting options for easy installation and replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If bulk materials are handled in hoppers or chutes, then material transport is achieved, but materials stick to walls causing flow blockages

Engineering Contradiction:

Improvematerial flow continuityVSAvoidflow blockage prevention

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The liner incorporates flexible fins or flaps that dynamically respond to material flow, moving with the flow to prevent materials from adhering to stationary surfaces. This dynamic configuration disrupts material flow patterns and prevents sticking, ensuring continuous flow without blockages.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The liner changes the surface parameters of the hopper or chute walls by providing a flexible, moving surface with different friction characteristics than rigid walls. The acute angle configuration and flexibility alter how materials interact with the surface, reducing adhesion and preventing blockages.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If bulk materials flow through hoppers or chutes, then material transport is achieved, but wear occurs to the panels requiring periodic repair or replacement

Engineering Contradiction:

Improvematerial transport efficiencyVSAvoidpanel service life

Core Design Contradiction:

ProductivityVSDuration of action of stationary object

Solution Approach 1:

The liner uses a flexible shell structure that conforms to the hopper or chute walls, providing a protective layer against wear. The flexible nature allows it to absorb impact and friction from flowing materials, significantly extending the service life of the underlying panels while maintaining material transport efficiency.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The liner is constructed from composite materials combining flexibility and wear resistance, creating a protective layer that withstands abrasive and impact forces from bulk materials while maintaining the structural integrity required for long-term service in material handling applications.

Inventive Principle:

Principle #40Composite materials

3Duration of action of stationary object

If traditional liner panels are installed in hoppers or chutes, then wear protection is provided, but replacement requires considerable downtime and expense

Engineering Contradiction:

Improvepanel service lifeVSAvoiddowntime for replacement

Core Design Contradiction:

Duration of action of stationary objectVSLoss of time

Solution Approach 1:

The liner system is segmented into modular panels or tiles that can be independently installed and replaced. This segmentation allows for quick replacement of only the worn sections without replacing the entire liner system, significantly reducing downtime and labor costs while maintaining extended service life through systematic replacement.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The flexible liner system ensures continuous flow of bulk materials, reduces wear on equipment, and allows for easy replacement, minimizing downtime and maintenance costs while being suitable for single-person installation and handling.

Implementation Method 1

uses the energy of the bulk materials to activate movement in flexible portion(s) of the flexible liner to lessen, or prevent, 'sticking' of the bulk materials to the walls

Methodology Applied

Scientific EffectKinetic energy transfer:

Implementation Method 2

The elongate body and the or each flexible fin or flap of each liner panel or tile are manufactured from elastomeric material

Methodology Applied

Scientific EffectImpact absorption:

Data Source

PatentUS7938244B2Flexible liner for hoppers or chutes

Publication Date: 2011.05.10 TRELLEBORG QUEENSLAND RUBBER

AI summary

A flexible liner (10) for a hopper or chute (40) has a plurality of overlapping flexible liner panels or tiles (20) secured to the walls (41,42) of the hopper or chute (40) by fixing strips (30). Each flexible liner panel or tile (20) has an elongate body (21) and a flexible fin or flap (22) formed integrally of elastomeric material, where the flexible fin or flap (22) extends at an acute included angle (α) (in the direction of flow of material through the hopper or chute (140)) to the side walls (41,42) and the Shore A hardness of the elongate body 21) is equal to, or greater than, the Shore A hardness of the flexible fin or flap (22).