Haul Truck Tray Polyurethane Coating for Lower-Weight Wear Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing haul truck wear liners are heavy, often made of large Hardox steel plates, which are inefficient in terms of weight and durability, and do not effectively address the high impact and stress issues during loading and dumping of abrasive materials.
Innovation Solution
A method for applying a lightweight protective coating to haul truck trays using a mould and jig framework, where the tray is heated and coated with a fluid polyurethane layer that cures to provide a seamless, high-strength, corrosion-resistant surface, enhancing structural integrity and absorbing vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional steel wear plates are used for protective coating, then strength and durability are improved, but weight increases significantly
Solution Approach 1:
The patent applies parameter changes by transitioning from solid steel plates to fluid polyurethane coating, changing the physical state and application method. The fluid coating is applied at controlled thickness (3-10mm) and cured to achieve the desired protective properties with reduced weight
Solution Approach 2:
The patent uses composite materials by combining polyurethane resin with reinforcing fibers or aggregates to create a protective coating that achieves steel-like strength and abrasion resistance while maintaining significantly lower weight compared to solid steel wear plates
2Manufacturing precision
If multiple-stage injection methods are used for coating, then complete coverage is achieved, but seams and weak points are created
Solution Approach 1:
The patent applies segmentation by dividing the coating process into distinct stages: initial coating application, vibration-assisted leveling, and secondary coating if needed. This segmented approach ensures complete coverage while maintaining structural integrity
Solution Approach 2:
The patent uses mechanical vibration during the coating process to level the fluid polyurethane coating and eliminate air pockets. The vibration causes the coating to self-level and conform to the tray surface, creating a seamless structure without weak points
3Ease of manufacture
If the tray is stationary during coating, then positioning is simple, but uniform coating distribution is difficult to achieve
Solution Approach 1:
The patent applies dynamics by making the tray movable during the coating process. The tray can be rotated or tilted to distribute the fluid polyurethane coating evenly across all surfaces, ensuring uniform thickness and complete coverage while maintaining simple positioning through controlled movement
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 method results in a stronger, lighter, and more durable haul truck tray with improved resistance to abrasion and corrosion, reducing the risk of damage from high impacts and stresses, thereby enhancing safety and operational efficiency.
Implementation Method 1
allowing the substantially uniform layer of fluid protective coating to cure
Implementation Method 2
heating at least a portion of the haul truck tray placed on the jig framework
Data Source
AI summary
Embodiments herein provide a method of applying a protective coating to a haul truck tray. The method includes (i) installing a mould on at least a portion of the haul truck tray, (ii) placing the at least a portion of the haul truck tray into a jig framework, (iii) heating at least a portion of the haul truck tray placed on the jig framework, (iv) providing a source of fluid protective coating at an elevated point on the at least a portion of the haul truck tray placed on the jig framework, (v) coating at least a portion of the haul truck tray surface with a substantially uniform layer of fluid protective coating, and (vi) allowing the substantially uniform layer of fluid protective coating to cure.