Wear-Resistant Rubber Lining With Interlocking Ceramic Projections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing process of conventional wear-resistant linings results in uneven grid-shaped joints due to ceramic pieces moving during vulcanization, leading to reduced functionality and increased risk of ceramic pieces cracking or peeling off under impact.
Innovation Solution
The wear-resistant lining features a resilient base layer with wear-resistant hard pieces arranged in lengthwise and crosswise directions, each with projections that contact adjacent pieces to maintain even gaps, ensuring uniform joint width and preventing independent movement of ceramic pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ceramic pieces are arranged on un-vulcanized rubber material and pressed during vulcanization, then the rubber material enters the gaps to form joints, but the ceramic pieces move in various directions causing uneven joint width
Solution Approach 1:
The patent applies preliminary action by pre-forming recesses in the ceramic pieces before arrangement. These recesses are strategically designed to receive protrusions from adjacent ceramic pieces, creating a pre-configured interlocking system that prevents movement during the vulcanization pressing process, thereby ensuring uniform joint width without complex arrangement procedures
Solution Approach 2:
The patent employs asymmetry by designing the recesses and protrusions with specific asymmetric geometries. The recesses have particular shapes and positions that correspond to protrusions of adjacent pieces, creating an asymmetric interlocking pattern that effectively restrains ceramic piece movement in all directions during pressing, thus achieving precise and uniform joint formation
2Reliability
If ceramic pieces are supported resiliently by the base layer, then impact from bumping objects is absorbed, but the joints may be peeled off due to shear force when adjacent pieces move in different directions
Solution Approach 1:
The patent applies composite materials by creating a hybrid structure that combines the resilient base layer with the rigid ceramic pieces featuring interlocking recesses and protrusions. This composite design allows the base layer to absorb impact forces while the interlocking mechanical features prevent relative movement between adjacent ceramic pieces, thereby preventing shear-induced joint peeling and maintaining both impact absorption and joint adhesion strength
Solution Approach 2:
The patent employs segmentation by dividing the ceramic lining into discrete pieces with interlocking features. Each ceramic piece is segmented to include specific recesses that engage with protrusions of neighboring pieces, creating a modular system where individual pieces can be supported resiliently by the base layer while maintaining fixed relative positions, thus preventing shear force from peeling joints during impact events
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 solution provides a wear-resistant lining with evenly formed grid-shaped joints that effectively absorb impact, reduce noise, and prevent ceramic pieces from cracking or peeling off, while maintaining adhesion and ensuring long-term functionality.
Implementation Method 1
Said rubber material 3 is vulcanized so that a plate-like resilient base layer 3a is formed for supporting bottoms of said ceramic pieces 4
Implementation Method 2
During vulcanization, the rubber material is plastically deformed and enters the gaps 5 between the adjacent ceramic pieces 4 with pressure to form the joints 3b
Implementation Method 3
The ceramic pieces 4 are supported resiliently by the base layer 3a so that strong impact by the bumping objects thrown in the hopper may be absorbed
Data Source
AI summary
A wear-resistant lining to be used as linings covering surfaces of an industrial apparatus where a wear-resistant quality is desired is provided. A wear-resistant lining is manufactured by such a process that a plate-like un-vulcanized rubber material (14M) and wear-resistant hard pieces (16) arranged thereon in lengthwise and crosswise directions with said gaps (15) formed the adjacent hard pieces are pressed and heated in a mold so that a resilient base layer (14) supporting the hard pieces as well as joints (18) filled in the gaps are formed by vulcanizing said rubber material. Each side-wall of said hard piece (16) is provided with at least one projection (19) which contacts with the side-wall of the adjacent hard piece (16) so that said gap (15) is formed to have a predetermined width (g) in which said joint (18) is formed, and said projections (19) of the hard pieces are embedded in said joints (18).


