Siloxane Polyethylene Discs for Cable Conveyor Oil Deposit Prevention
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Solution Overview
Problem
Cable conveyor systems face issues with black-colored deposits on the tubing interior when conveying materials containing oil, which existing discs made of materials like nylon and high molecular weight polyethylene fail to prevent effectively.
Innovation Solution
The use of polymer discs formed from a resin blend of high molecular weight siloxane and ultra-high molecular weight polyethylene, with siloxane present in specific weight percentages, which are designed to slideably engage the tube interior and prevent oil-related deposits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional discs made of nylon or high molecular weight polyethylene are used, then the cable conveyor can operate continuously, but black deposits form on the tubing interior when conveying oil-containing materials
Solution Approach 1:
The patent applies composite materials by creating a disc made from a resin blend combining ultra-high molecular weight polyethylene (97-99.5%) with siloxane (0.5-3.0%). This composite material integrates the high molecular weight polyethylene's durability and load-bearing capacity with siloxane's oil-resistant properties, enabling the disc to prevent black deposit formation while maintaining continuous operation capability. The specific blend ratio optimizes both the structural integrity needed for continuous operation and the oil resistance needed to prevent deposits.
Solution Approach 2:
The patent applies parameter changes by modifying the chemical composition parameters of the disc material. Specifically, it changes the molecular weight of polyethylene to ultra-high molecular weight (3-8 million grams/mol) and introduces siloxane with specific viscosity (10,000-1,000,000 cst.) at controlled concentrations (0.5-30.0%). These parameter changes transform the material's interaction with oil, preventing the chemical reactions that cause black deposit formation while maintaining operational continuity.
2Strength
If discs are made from high molecular weight polyethylene, then they provide adequate strength and durability, but they fail to prevent oil-related black deposits on the tubing surface
Solution Approach 1:
The patent resolves this contradiction by creating a composite material that combines ultra-high molecular weight polyethylene (maintaining strength and durability) with siloxane (preventing oil-related black deposits). The composite structure allows the disc to retain the mechanical properties of high molecular weight polyethylene while gaining the oil-resistant characteristics of siloxane, thereby simultaneously achieving both strength and prevention of harmful deposits.
Solution Approach 2:
The patent applies local quality by introducing siloxane as a specific additive component within the polyethylene matrix at controlled concentrations (0.5-3.0%). This localized incorporation of siloxane provides oil-resistant properties at the interface where the disc contacts the tubing and conveyed material, while the bulk polyethylene structure maintains the required strength and durability. The siloxane acts locally at the surface and interface zones to prevent deposit formation.
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 polymer discs effectively prevent the formation of black deposits on the tubing surface during the conveyance of oil-containing materials, outperforming traditional discs by maintaining cleanliness for several hours.
Implementation Method 1
The polymer discs effectively prevent the formation of black deposits on the tubing surface during the conveyance of oil-containing materials
Implementation Method 2
When the conveyed material contains oil, a black-colored deposit may appear on the interior surface of the tubing
Data Source
AI summary
A disc for a cable conveyor comprised of a polymer formed from a resin including a blend of siloxane, and polyethylene. The siloxane may be a high molecular weight siloxane having a viscosity ranging from 10,000 cst. to 1,000,000 cst., preferably about 500,000 cst., and the polyethylene may be an ultra-high molecular weight polyethylene having a molecular weight ranging from 3 million grams/mol. to 8 million grams/mol., preferably about 3.5 million grams/mol. The siloxane is present in the blend from 0.5 percent to 30.0, preferably about 3.0 percent.