Patent Publication Number: US-10315849-B2

Title: Conveyor chain

Description:
PRIORITY 
     This application is a continuation of U.S. patent application Ser. No. 14/577,587, entitled “CONVEYOR CHAIN”, filed Dec. 19, 2014; which application is a continuation-in-part Application of U.S. patent application Ser. No. 14/445,981, entitled “CONVEYOR CHAIN”, filed Jul. 29, 2014, now U.S. Pat. No. 9,227,787 issued Jan. 5, 2016; which application is a continuation-in-part Application of U.S. patent application Ser. No. 13/908,343, entitled “CONVEYOR CHAIN”, filed Jun. 3, 2013, now U.S. Pat. No. 8,936,146 issued Jan. 20, 2015; which application is a continuation-in-part application of U.S. patent application Ser. No. 12/559,799, entitled “CONVEYOR CHAIN”, filed Sep. 15, 2009, now U.S. Pat. No. 8,453,826, issued Jun. 4, 2013; which application claims priority to U.S. Provisional Patent Application Ser. No. 61/098,1870, filed Sep. 22, 2008, entitled “CONVEYOR CHAIN,” and U.S. Provisional Patent Application Ser. No. 61/234,398, filed Aug. 17, 2009, entitled “CONVEYOR CHAIN,” the applications, patent, and disclosures of which are incorporated by reference herein in their entireties. 
    
    
     BACKGROUND 
     Pusher-type chain conveyors, as used in the mining industry, are found both in the form of separate conveying units, and as integral parts of continuous mining machines. One example of a continuous mining machine is a self-propelled mining machine. It is provided at its forward end with cutting means shiftable in such a way that an entry is cut in the material being mined. The entry is so sized as to permit passage of the mining machine therethrough. Since the cutting operation is a continuous one, it is advantageous to provide means to move the cut material from in front of the mining machine and to convey it out of the entry. 
     One or several conveyors may be incorporated into the mining machine&#39;s construction that acts successively to transport the cut material rearwardly from the machine. One example of a conveyor that is incorporated into the mining machine extends from the front to the rear of the machine. The purpose of this conveyor is to remove the cut material from entry and deliver the cut material to other conveying means. The other conveying means may comprise mine cars or other vehicles used for hauling, portable belt conveyors or other conveyors designed for loading and unloading mined material from the mining machine, or the like. 
     An example of a conveyor that has been encountered in association with a continuous mining machine includes a section of conveyor base means mounted on the mining machine body. One or more additional sections of conveyor base means are connected thereto end-to-end, and extend beyond the rearward end of the mining machine body. All of the base means sections are characterized by a bottom portion provided with longitudinally extending, upstanding side guides or flanges. The various sections of the tail conveyor can be capable of both lateral and vertical movement with respect to each other, which enables the cut material to be delivered to a desired point despite changes of position of the mining machine as it advances in the entry and changes in level of the entry floor. The lateral and vertical movement capability of the conveyor sections may also enable the shifting of the desired delivery point for the material being mined, as required. 
     This type of conveyor may incorporate a continuous pusher-type conveyor chain, which is driven along the length of the conveyor base sections. The chain may be provided with a plurality of rigid pusher elements, normally extending substantially transversely of the conveying direction. The pusher elements are located at spaced intervals along the chain. Adjacent pusher elements may be joined together by a series of alternate block-like links and plate-like links. At one end of the machine&#39;s conveyor, the continuous chain passes over a driven sprocket. At the other end of the conveyor, the chain passes over a driven or idler sprocket, or roller. 
     Various embodiments of a conveyor chain configured to be used in conjunction with a dual drive sprocket on a mining machine are disclosed in the following applications: U.S. Provisional Patent Application No. 60/238,877, filed Oct. 6, 2000; PCT Patent Application Serial No. PCT/US01/31746, filed Oct. 9, 2001; and U.S. Nonprovisional patent application Ser. No. 10/398,387, which was filed on Apr. 7, 2003 and is now issued as U.S. Pat. No. 8,016,102; the disclosures of which are incorporated by reference herein. 
     Typically in the underground mining industry, machine downtime is very expensive. Should a conveyor chain fail (due to sudden impact or wear), the chain often would come apart during production causing several hours of expensive and unproductive downtime while the chain was repaired. Most often a conveyor chain fails from impact loads on the flight arms or other parts of the chain. 
     Accordingly, it is desirable to provide a conveyor chain that has specific features and structures to provide a robust design which functions as desired, are quiet, and will not fail under rigorous usage. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate speech recognition system components and embodiments of the invention and, together with the detailed description of the embodiments given below, serve to explain the principles of the invention. 
         FIG. 1  is a plan view of a typical continuous mining machine having a tail conveyor for initializing the chain of the invention. 
         FIG. 2  depicts a perspective view of a segment of an exemplary conveyor chain in accordance with an embodiment of the invention. 
         FIG. 3  depicts a perspective view of an exemplary side strap of an embodiment of the invention. 
         FIG. 4  depicts a perspective view of an exemplary connecting pin of an embodiment of the invention. 
         FIG. 5  depicts a perspective view of an exemplary universal link of an embodiment of the invention. 
         FIG. 5A  is a top view of an exemplary universal link of an embodiment of the invention. 
         FIG. 5B  is a side view of the exemplary universal link of  FIG. 5A . 
         FIG. 6  depicts a perspective view of an exemplary connector link of an embodiment of the invention. 
         FIG. 6A  is a top view of an exemplary connector link of an embodiment of the invention. 
         FIG. 6B  is a side view of the exemplary connector link of  FIG. 6A . 
         FIG. 7  depicts a perspective view of an exemplary universal connector assembly of an embodiment of the invention. 
         FIG. 8  depicts a side cross-sectional view of the exemplary universal connector assembly of  FIG. 7  of an embodiment of the invention. 
         FIG. 9  depicts a top plan view of an exemplary flight arm of an embodiment of the invention. 
         FIG. 10  depicts a side elevation view of the exemplary flight arm of  FIG. 9  of an embodiment of the invention. 
         FIG. 11  depicts an end view of the exemplary flight arm of  FIG. 9  of an embodiment of the invention. 
         FIG. 12  depicts a perspective view of an exemplary flight pin of an embodiment of the invention. 
         FIG. 13  depicts a perspective view of a section of exemplary conveyor chain engaged with an exemplary driving member comprising a dual drive sprocket of an embodiment of the invention. 
         FIG. 14  depicts a perspective view of a section of exemplary conveyor chain engaged with an exemplary driving member comprising a triple drive sprocket of an embodiment of the invention. 
         FIG. 15A  is an exploded perspective view of an exemplary side link assembly of an embodiment of the invention. 
         FIG. 15B  is a side view of the exemplary side link assembly of  FIG. 15A . 
         FIG. 16  is an exploded perspective view of an exemplary side link assembly of an embodiment of the invention. 
         FIG. 17  is a perspective view of a segment of an exemplary conveyor chain in accordance with an embodiment of the invention. 
         FIG. 18  is a perspective view of a segment of an exemplary conveyor chain in accordance with another embodiment of the invention. 
         FIG. 19  is another perspective view of a portion of the exemplary conveyor chain illustrated in  FIG. 18 . 
         FIG. 20  is an exploded perspective view of a portion of the exemplary conveyor chain illustrated in  FIG. 19 . 
         FIG. 21  is a top cross-sectional view of the solid articulating connector of  FIG. 22  in accordance with one embodiment of the invention. 
         FIG. 22  is a side view of the solid articulating connector of  FIG. 20  to provide articulation in a conveyor chain. 
         FIG. 23  is a top perspective view of another embodiment of a solid articulating connector in accordance with the invention. 
         FIG. 24  is a perspective view of a segment of another exemplary conveyor chain in accordance with an embodiment of the invention. 
         FIG. 25  is a top perspective view of another embodiment of a solid articulating connector of the invention. 
         FIG. 26  is a perspective view of a segment of another exemplary chain, in accordance with an embodiment of the invention. 
         FIG. 27  is a perspective view of a segment of another exemplary conveyor chain in accordance with an embodiment of the invention. 
         FIG. 28  is a perspective view of a segment of an exemplary conveyor chain in accordance with another embodiment of the invention. 
         FIG. 29  is a perspective view of another embodiment of a solid articulating connector in accordance with the invention. 
         FIG. 30  is a top cross-sectional view of the solid articulating connector of  FIG. 29  in accordance with one embodiment of the invention. 
         FIG. 31  is a side view of the solid articulating connector of  FIG. 29  to provide articulation in a conveyor chain. 
         FIG. 32  is another perspective view of a portion of the exemplary conveyor chain illustrated in  FIG. 28 . 
         FIG. 33  is an exploded perspective view of a portion of the exemplary conveyor chain illustrated in  FIG. 32 . 
         FIG. 34  is an end view of the solid articulating connector of  FIG. 29  to provide articulation in a conveyor chain. 
         FIG. 35  is a top cross-sectional view of the solid articulating connector of  FIG. 29  in accordance with one embodiment of the invention 
     
    
    
     The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown. 
     DETAILED DESCRIPTION 
     The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which is by way of illustration, one of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive. 
     For better understanding of the invention, reference is first made to  FIG. 1 , illustrating an exemplary environment for the chains of the present invention.  FIG. 1  diagrammatically illustrates a typical continuous mining machine generally indicated at  2  and provided with a tail conveyor, generally indicated at  3 . The mining machine has a body portion  4  which is usually mounted on wheels or treads and is self-propelled. At the forward end of the mining machine, cutting elements are provided as shown at  5  and  6 . These cutting elements  5  and  6  may take various well known forms and are suitably mounted such as on the frame  7 , enabling the cutting means to be shifted in such a way that they will cut an entry large enough to receive and to permit advancement of the mining machine  2  in the cutting direction indicated by arrow A. 
     By various well-known conveying means, the cut material at the forward end of the mining machine is gathered and transported over or through the mining machine to the tail conveyor  3 . This last mentioned conveyor comprises a conveyor base element, illustrated in  FIG. 1  as made up of two sections  8  and  9 . The base element section  8  has a bottom portion  10  and upstanding side guide or flanges  11  and  12 . Similarly, the section  9  has a bottom portion  13  and upstanding side guides or flanges  14  and  15 . The section  9  is mounted on a boom  16  articulated to the rearward end of the mining machine body  4  as at point  17 . The articulation is such that the boom  16  and its conveyor base element section  9  are shiftable with respect to the conveyor base element section  8  both in the vertical plane and the horizontal plane. A pusher-type conveyor chain, generally indicated at  18 , extends along the length of the conveyor base element sections  8  and  9  and is adapted to be driven along the upper surface of their bottom portions  10  and  13 . It will be understood that the chain  18  is a continuous chain. Normally it will be driven by a sprocket positioned at least at one end of the tail conveyor  3 . 
     As shown in  FIG. 1 , a typical chain  18  is provided with a plurality of spaced pusher elements arms  19 , extending substantially transversely of the conveying direction indicated by arrow B. It will be seen that the pusher elements preferably extend to both side if the chain  18  and that the pusher elements are located at predetermined intervals along the length of the chain. 
       FIG. 2  illustrates a section of a conveyor chain  25  for use in a device such as that illustrated in  FIG. 1 . The chain section illustrated in  FIG. 2  comprises two side link assemblies  35 , four connector assemblies  40 , and two flight arm assemblies  50 . Of course, conveyor chain  25  will comprise any suitable number of side link assemblies, connector assemblies, and flight assemblies to produce a chain of sufficient length for a particular application. It will be appreciated that there is some appropriate duplication in the link assemblies. For example, side strap  33  may be virtually identical to side strap  34  in the side link assembly. In the illustrated embodiment, each universal connector assembly  40  comprises a universal link  42  ( FIG. 5 ) and a connector link  43  ( FIG. 6 ) with a universal pin  41  ( FIG. 7 ) extending through the universal link  42  and the connector link  43 . As shown in  FIG. 2 , each flight arm assembly  50  comprises a pair of flight arm pins  51 ,  52  and a pair of flight arms  53 ,  54 . 
     In the illustrated embodiment, the two side straps  33 ,  34  of each side link assembly  30  are spaced apart and positioned so that the two side strap bosses  37 ,  38  are facing outwardly with respect to a center line of the chain. In this example, each side strap boss  37 ,  38  comprises a hollow circular protrusion that includes an opening  39  that extends through the side strap boss  37 ,  38  and through base  35 . Each side strap boss  37 ,  38  is configured to receive at least a portion of a connecting pin  31 ,  32 . The connecting pins span between the side straps and connect the opposing side straps. Of course, side strap bosses  37 ,  38  may comprise any suitable shape, including but not limited to circular and square. 
     As shown in  FIGS. 13 and 14 , when the chain is driven, the side strap bosses  37 ,  38  are configured to engage a tooth  112  of a sprocket, such as one of sprockets  114   a ,  114   b  of drive mechanism  100  or outer sprockets  214   a ,  214   b  of drive mechanism  200 . The chain is engaged and driven by a suitable driving member, such as a dual drive sprocket  100   FIG. 13 , a triple drive sprocket  200   FIG. 14  or any other suitable driving member. The chain of the present invention is configured to be able to handle both a dual drive sprocket arrangement, as illustrated in  FIG. 13 , or a triple drive sprocket arrangement as in  FIG. 14  depending on its use. In the illustrated embodiments, the side strap  33  in each side link assembly  30  is aligned with side strap  34  such that each side strap boss  37 ,  38  of side strap  33  is aligned with a corresponding side strap boss  37 ,  38  of side strap  34 . In the embodiments, a first connecting pin  31  is inserted through the aligned side strap bosses  37  in side straps  33 ,  34 , while a second connecting pin  32  is inserted through the aligned side strap bosses  38  in side straps  33 ,  34 . Collectively, the side straps  33 ,  34  and connecting pins  31 ,  32  form a side link assembly  30 . 
     The diameter of the connecting pins  31 ,  32  may be about 1⅛ inch, or any other suitable dimension. By way of example only, in some embodiments the diameter of the connecting pin  31 ,  32  may range from about 1 inch to about 1¼ inch. Increasing the diameter of the connecting pins  31 ,  32  compared to bearing pins used in existing conveyor chains will improve the strength and reliability of the conveyor chain during operation while reducing the chance of chain breakage. The connecting pins  31 ,  32  and side strap bosses  37 ,  38  may be configured to provide a press fit, a sliding close tolerance fit, or any other suitable fit between the components to form the complete side link assembly. Connecting pins  31 ,  32  may be retained within side strap bosses  37 ,  38  by keeper pins, retaining rings, by press fit alone, or by any other suitable method or device. In one embodiment a ring is press fit onto the end of the connecting pin to engage groove  21  and hold the pins in the side straps  33 ,  34  of the side link assemblies (see  FIG. 4 ). 
     While the embodiment of the invention is illustrated in  FIG. 2  shows connecting pins  31 ,  32  that are retained within the side strap bosses  47 ,  48  by a press fit ring and a ring  23 ,  FIGS. 15A, 15B and 16  illustrate alternative embodiments to the invention wherein alternative securing elements are utilized with the connecting pins,  31 ,  32  for forming the side link assembly  30 . Specifically, as illustrated in  FIG. 15A , the connecting pins  31 ,  32  are inserted into the corresponding and aligning side strap bosses  37 ,  38  of the opposing side straps  33 ,  34 . The connecting pins  31 ,  32  include connector grooves  21  formed therein at each end. When the connecting pins  31 ,  32  extend through the side strap bosses  37 ,  38 , the corresponding grooves  21  at either end of the connecting pins are exposed adjacent the end of the respective bosses  37 ,  38 . Retaining rings  80  in the form of external retaining are expandable rings that may be expanded or spread apart, are appropriately positioned around an end of the connecting pins  31 ,  32  and are then dimensioned in an unexpanded state to engage the grooves  21  and fit snuggly against the ends of the bosses  37 ,  38  to secure the connecting pins in the side straps  33 ,  34 . The retaining rings  80  are illustrated in  FIGS. 15A and 15B  on one side of the assembly  30 , but it will be readily understood that the retaining rings are implemented on both ends of the connecting pins  31 ,  32  for holding the pins in each of the side straps  33 ,  34 . The external retaining rings or snap rings  80  may be formed with a suitably strong material such as stainless steel and may have an inner diameter around 1 1/16 inches.  FIG. 15B  illustrates a side view of side link assembly  30  with rings  80  in place with the connecting pins  31 ,  32 . 
     Turning now to  FIG. 16 , that figure illustrates a side link assembly  30  and incorporates other retaining elements. Specifically, one or more spiral retaining rings  82  are utilized to fit into the grooves  21  of connecting pins  31 ,  32 . The spiral retaining ring may be single turn or multi-turn spiral retaining rings. As illustrated in  FIG. 16 , multiple spiral rings might be utilized to hold the connecting pins  31 ,  32 . Alternatively, only a single spiral retaining ring might be utilized in the embodiment as shown in  FIG. 16 . The external retaining rings  80  and spiral retaining rings  82  provide for an easier disassembly of the side link assembly such as for replacement or repair. The rings,  80 ,  82  may be removed and re-installed numerous times without destroying the rings or weakening their engagement with the pins. 
       FIGS. 5-8  depict one embodiment of a universal connector assembly  40 . In the illustrated embodiment, universal connector assembly  40  comprises a universal pin  41 , a universal link  42 , and a connector link  43 . The universal link  42  as pictured in  FIG. 5 , comprises an upper lip  61  and lower lip  62  each having a vertical thru-hole  63 ,  64  that is configured to receive at least a portion of the universal pin  41 . The universal link  42  can also be described as the female link. In this example, universal link  42  further comprises connecting portion  65  that extends between upper lip  61  and lower lip  62 . As shown, connecting portion  65  is rounded and has an inside surface that forms a horizontal bore/thru-hole  67  configured to receive at least a portion of a connecting pin  31 ,  32  of a side link assembly or a flight pin  51 ,  52  of a flight arm assembly. The universal link  42  also includes a groove  45  formed on the outside surface of the connecting portion  65 . The groove  45  of universal connector assembly  40  provides a surface for engagement by a center or third sprocket for driving the chain discussed herein. In the illustrated embodiment, connector link  43  comprises a projecting member  71  sized and shaped to fit between the upper lip  61  and lower lip  62  of the universal link  42  as shown in  FIG. 7 . The connector link  43  can also be described as a male link. In this version, projecting member  71  includes a vertical bore or thru-hole  72  that is configured to receive a universal pin  41 . In this example, connector link  43  further comprises a horizontal bore or opening  73  that extends through the width of connector link  43  and is configured to receive at least a portion of a connecting pin  31 ,  32  or a flight pin  51 ,  52 . The connector link  43  also includes a groove  47  formed on an end of the connector link opposite the projecting member. Groove  47  also provides a surface for engagement by a center/third sprocket for driving the chain if desired. 
     As shown in  FIGS. 7 and 8 , when universal connector assembly  40  is fully assembled, the projecting member  71  of the connector link  43  is inserted between the upper lip  61  and lower lip  62  of the universal link  42 . In this example, vertical thru-holes  63 ,  64  of the universal link  42  are axially aligned with vertical thru-hole  72  of the connector link, such that the universal pin  41  may pass through the vertical thru-holes  64 ,  63 ,  72  as shown in  FIGS. 7 and 8 . The universal pin  41  may be configured to increase mobility of the chain, allow the chain to articulate past objects, and reduce the load transmitted to the connecting pins  31 ,  32  when an obstruction in a conveying deck is encountered. 
       FIGS. 5A-5B and 6A-6B  illustrate alternative universal links and connector links respectively in accordance with another embodiment of the invention. Specifically, the universal link  42   a  and connector link  43   a  include thru-holes or bores that are induction hardened to have a greater hardness than the remaining portions of the respective links. For example, referring to  FIGS. 5A and 5B , the horizontal bore or thru-hole  67  is hardened at a specific depth around the bore to a greater hardness rating than the rest of the link. For example, while the universal link  42   a , after machining, might have a hardness of around 40-44 on the Rockwell C Scale (40-44 Rc) the thru-hole bore  67  might be induction hardened to have a hardness rating of around 50-54 Rc. In accordance with one embodiment of the invention, such hardness may be induced to a depth D of ⅛ inch to 3/16 inches deep around the thru-hole and completely through that hole  67 . 
     Connector link  43   a  as shown in  FIGS. 6A-6B  might also be hardened in accordance with an embodiment of the invention. To that end, vertical bore or thru-hole  72  and horizontal bore or opening  73  might also be hardened to a hardness of 50-54 Rc around the bore or hole to a depth D of ⅛ inch to 3/16 inches. 
     In accordance with an aspect of the invention, the localized bore or thru-hole hardening in the links,  42   a ,  43   a  of a universal connector assembly with respect to the overall link elements will reduce the wear in those various high bore and wear areas where the pins  41  and  31 ,  32 ,  51 ,  52  engage and thus extend the overall life of the chain. Generally, a universal pin  41 , as illustrated in  FIG. 7 , is held in place in holes  63 ,  64 , such as by a weld  49 . Therefore the hardening of hole  72  provides desirable wear resistance. Similarly, as the hole  67  and opening  73  rotate around connecting pins  31 ,  32  or flight pins  51 ,  52 , the hardening of those holes and openings provide additional wear resistance to extend the overall life of the chain. When the various elements of the universal connector assembly are hardened, they are induction hardened by positioning a coil in the various holes or bores introducing significant heat, such as around 1600° Fahrenheit to that coil. The temperature and length of time of the induction hardening may be adjusted accordingly in order to achieve the desired depth of induction hardening of the noted bores and thru-holes. 
     As shown in  FIG. 2 , flight arm assembly  50  comprises a pair of flight pins  51 ,  52  and a pair of flight arms  53 ,  54  positioned on either side of the chain. In the example of  FIGS. 9-11 , each flight arm  53 ,  54  comprises an elongated body  55  extending substantially perpendicular from an integral base  56 . In this embodiment, each base  56  includes a pair of flight arm attachment apertures  57 ,  58  or pockets that extend transversely through the base  56 . Each flight arm attachment aperture  57 ,  58  may be configured to receive at least a portion of one of the flight pins  51 ,  52 . As shown, each base  56  further comprises a vertical sprocket opening  59  that is formed through the base and extends vertically through the base  56 . The diameter of the flight pin may be about 1⅛ inch, or any other suitable dimension. By way of example only, in some embodiments the diameter of the flight pin  51 ,  52  may range from about 1 inch to about 1¼ inch. Increasing the diameter of the flight pins  51 ,  52  compared to bearing pins used in existing conveyor chains will improve the strength and reliability of the conveyor chain during operation while reducing the chance of chain breakage. The flight pins  51 ,  52  and bases  56  may be configured to provide a press fit, a sliding close tolerance fit, or any other suitable fit between the components. Flight pins  51 ,  52  may be retained within the flight arm attachment apertures  57 ,  58  of bases  56  by keeper pins, welding by press fit, by press fit and weld, or by any other suitable method or device. 
     As shown in  FIGS. 9-11 , flight arm  53 ,  54  comprises an elongated body  55  having a flat, planar bottom surface  111  and an integral base  56 . In this version, elongated body  55  comprises a central rib  101  that may act as a pusher for the material being conveyed. In this example, the outer free end of flight arm  53 ,  54  is provided with a knob-like portion  102  which can ride against side guide elements associated with the conveyors. The base  56  may be provided with a vertical sprocket opening  59 . As shown in  FIGS. 13 and 14 , sprocket opening  59  is sized and shaped to engage a tooth  112  of a drive sprocket such as one of sprockets  114   a ,  114   b  of driving member  100  or sprockets  214   a ,  214   b  of driving member  200  when the chain is engaged and driven by a suitable driving member, such as a dual drive sprocket  100 , a triple drive sprocket  200  or any other suitable driving member. While sprocket opening  59  is substantially rectangular in the illustrated embodiment, it will be appreciated that sprocket opening  59  may comprise any suitable shape configured to receive and engage a tooth  112 , including but not limited to circular, oval, square, and rectangular. The base  56  also has a groove  61  formed in the base  56  along a bottom of the base for proper engagement and clearance of any sprocket teeth  102 . In the illustrated version, base  56  also comprises the two flight arm attachment aperture  57 ,  58 . As shown in  FIG. 2 , flight arm  53  in each flight arm assembly  50  is aligned with flight arm  54  on the other side of the chain such that the flight arm attachment apertures  57 ,  58  of flight arm  53  are aligned with the flight arm attachment apertures  57 ,  58  of flight arm  54 . In this example, a first flight pin  51  is inserted through the aligned flight arm attachment apertures  57  in flight arms  53 ,  54 , while a second flight pin  52  is inserted through the aligned flight arm attachment apertures  58  in the flight arms  53 ,  54 . In addition, each of the flight pins  51 ,  52  are inserted through appropriate horizontal openings  73  of a pair of connector links  43  or holes  67  a pair of universal links positioned between the flight arms  53 ,  54 . 
     As shown in  FIG. 2 , section of conveyor chain  25  comprises a plurality of alternating side link assemblies  30  and flight arm assemblies  50  connected by connector assemblies  40 . In this version, each universal connector assembly  40  is configured and arranged to be connected to both a side link assembly  30  and a flight arm assembly  50 . In this example, conveyor chain  25  comprises a side link assembly  30  connected to a first universal connector assembly  40 , a flight arm assembly  50  connected to both the first universal connector assembly  40  and a second universal connector assembly  40 , and the second universal connector assembly  40  is connected to a second side link assembly  30  and so on in a repeating pattern. While the illustrated version depicts a chain comprising alternating side strap assemblies  30  and flight arm assemblies  50 , it will be appreciated that a section of chain may comprise any suitable arrangement of side strap assemblies  30  and flight arm assemblies  50 . By way of example only, in an alternate embodiment (not shown), a section of conveyor chain may comprise two side strap assemblies positioned between a pair of flight arm assemblies. As shown in  FIG. 2 , a side link assembly  30  is connected to a universal connector assembly  40  via a connecting pin  32 . In this version, connecting pin  32  is positioned such that it passes through the aligned side strap bosses  38  of side straps  33 ,  34  and the opening  67  formed by connecting member  65  of universal link  42 . (Alternatively, a side link assembly  30  may be connected to a universal connector assembly  40  via a connecting pin  31  such that connecting pin  31  is positioned so that it passes through the aligned side strap bosses  37  of side straps  33 ,  34  and the horizontal opening  73  in connector link  43 .) Similarly, flight assembly  50  may be connected to a universal connector assembly  40  by positioning a flight pin  51 ,  52  through a pair of aligned flight arm attachment apertures  57 ,  58  in two opposing flight arms  53 ,  54  and the horizontal opening  73  in connector link  43 . (Alternatively, a flight assembly  50  may be connected to a universal connector assembly  40  by positioning a flight pin  51 ,  52  through a pair of aligned flight arm attachment apertures  57 ,  58  in two opposing flight arms  53 ,  54  and the opening  67  formed by connecting member  65  in a universal link  42 .) 
       FIG. 17  illustrates another embodiment of the invention. Chain  250  is similar to the chains described herein in many details but also incorporates flight assemblies having an alternative construction. Specifically, chain  250  incorporates flight arm assemblies  260  that incorporate flight arms that are covered in a suitable urethane material  270 . The urethane material, in accordance with one aspect of the invention, provides for a reduction in the noise generated when the chain  250  is in operation. While chain  250 , incorporates different flight arm assemblies  260 , other components of the chain, such as the side link assemblies and universal connector assemblies may be constructed as noted herein. Each of the flight arm assemblies  260  includes a pair of flight pins  51 ,  52  as discussed above. Each of the flight arms  262  also includes an elongated body  264  which extends substantially perpendicular from an integral base  266 . Base  266  may resemble base  56  illustrated in other figures and discussed herein. That is, the base includes a pair of flight arm attachment apertures  57 ,  58  that extend transversely through the base. Each base also includes a vertical sprocket opening  59  that is formed through the base and extends vertically therethrough, such as to receive the teeth of drive sprockets. 
     Each flight assembly  260  includes a layer of urethane material  270  that is formed or appropriately applied to the elongated body  262  of the flight arms. The elongated body  262  incorporates a series of apertures that are formed in the body  262 . The embodiment illustrated in  FIG. 17  shows 5 apertures, including apertures  272  having a circular diameter of 1.25 inches and two larger apertures  274  having a circular diameter of approximately 2 inches. The apertures are formed through each of the flight arms from top to bottom and provide passages for the flow of urethane material therethrough to form an integral attachment of the urethane material layer  270  to the flight arm bodies  262 . For example, the urethane material may be flowed or formed over the flight arm bodies  262  in a liquid or semi liquid form which flows or extends through the apertures  272 ,  274 . The urethane material then hardens and secures the material layer  270  to the flight arm  262  to become an integral part of the flight assembly  260 . The urethane material layer is illustrated over most or all of the elongated body of the flight arm, but urethane material might be used over at least a portion of the elongated body. It would be understood by person of ordinary skill in the art that apertures having a shape or cross section that is different than a circular cross section may be implemented. Furthermore, a greater or lesser number of apertures may be utilized along the length of the flight arm bodies  262 . Still further, different sizes of apertures may be implemented along the length of the flight arm bodies  262 , therefore the invention is not limited to the number, size or shape of the apertures formed in the flight arm as illustrated in the example of the Figures. Each flight arm body  262  has a generally flat upper surface  276  and lower surface  278 . Similarly, the urethane material layer  270  in the embodiment illustrated in  FIG. 17 , is shown to have a similar flat upper, lower surface conforming with the surfaces  276 ,  278  of the flight arm bodies  262 . In that way, the flight arm slides freely along a conveyor surface. Also, although the urethane material layer  270  illustrated in  FIG. 17  is shown to be somewhat clear, thus revealing the elongated the flight arm bodies  262 , urethane material  270  might also be opaque in order to hide the internal flight arm body  262 . 
     In another alternative embodiment of the invention, elements of the chain are covered with a corrosion protective coating. For example, the elements might be galvanized, or maybe covered with a nickel coating. In one embodiment, various connecting pins  31 ,  32  and flight pins  51 ,  52  as well as the universal pin  41 , universal link  42  and connector link  43  are all coated as appropriate for protection against corrosion. Additionally, the elements of the side link assembly, including the base  35  and side strap bosses  37 ,  38  and any internal openings  39  may be coated with a suitable corrosion protective coating. 
     As shown in  FIG. 13 , conveyor chain  115  is driven by a driving member  100 . In this example, driving member  100  comprises a dual drive sprocket that includes sprockets  114   a ,  114   b . It will be appreciated that driving member  100  may comprise any suitable number of sprockets, including but not limited to a dual drive sprocket as shown in  FIG. 13 , a triple drive sprocket as shown in  FIG. 14 , or any other suitable number of sprockets. It will further be appreciated that driving member may comprise any suitable size sprockets, including but not limited to a four tooth sprocket, five tooth sprocket, a six-tooth sprocket, an eight tooth sprocket, and various combinations thereof. Use of a dual drive sprocket, such as driving member  100  shown in  FIG. 13 , and a corresponding conveyor chain configured to be used with a dual drive sprocket, such as conveyor chains  25 ,  115 ,  205 , may reduce operational noise and improve sprocket tooth life. The two sprockets  114   a ,  114   b  comprising driving member  100  may be substantially identical to each other and configured to rotate in unison with each other. By way of example only, in the embodiments shown in  FIG. 13 , sprockets  114   a ,  114   b  are each eight-tooth sprockets. 
     As shown, sprockets  114   a ,  114   b  are spaced apart so that they are aligned with the side strap bosses  37 ,  38  and the vertical sprocket openings  59  along each side of the chain  115 . In the illustrated embodiment, as conveyor chain  115  wraps around driving member  100 , each sprocket tooth  112  engages a side strap boss  37 ,  38  or the base  56  of a flight arm  53 ,  54  via a vertical sprocket opening  59  along both sides of the chain  115 . As shown, a first sprocket tooth  112  may abut a first side strap boss  37 , while a second sprocket tooth  112  may abut a second side strap boss  38 , while a third sprocket tooth  112  may be received by and extend at least partially through a vertical sprocket opening  59 . Although not shown in  FIG. 13 , additional sprocket teeth may engage additional side strap bosses and vertical sprocket openings as the chain wraps around the dual sprocket. In the illustrated embodiment, the sprocket teeth  112  do not directly engage or contact connecting pins  31 ,  32 ) or flight pins  51 ,  52 . Because the points of engagement between conveyor chain  115  and sprocket teeth  112  (i.e. side strap bosses  37 ,  38  and flight arm bases  56 ) are thicker than the points of engagement in some prior art conveyor chains (where sprocket teeth directly engage bearing pins in the chain), conveyor chain  115  may provide improved chain life and strength. 
     As shown in  FIG. 14 , conveyor chain  205  is driven by a driving member  200 . In this example, driving member  200  comprises a triple drive sprocket that includes two outer sprockets  214   a ,  214   b  and a central sprocket  214   c . It will be appreciated that driving member  200  may comprise any suitable number of sprockets, including but not limited to a dual drive sprocket as shown in  FIG. 13 , a triple drive sprocket as shown in  FIG. 14 , or any other suitable number of sprockets. It will further be appreciated that the driving member may comprise any suitable size sprockets, including but not limited to a four tooth sprocket, five tooth sprocket, a six-tooth sprocket, an eight tooth sprocket, and various combinations thereof. Use of a triple drive sprocket, such as driving member  200  shown in  FIG. 14 , and a corresponding conveyor chain configured to be used with a triple drive sprocket, such as conveyor chains  25 ,  115 ,  205 , may reduce operational noise and improve sprocket tooth life. The two outer sprockets  214   a ,  214   b  may be substantially identical to each other, while central sprocket  214   c  may be configured to have half as many sprocket teeth as outer sprockets  214   a ,  214   b . Other suitable relationships between the outer sprockets and the central sprocket may be apparent to those of ordinary skill in the art. All three sprockets  214   a ,  214   b ,  214   c  may be configured to rotate in unison with each other. By way of example only, in the embodiment shown in  FIG. 14 , outer sprockets  214   a ,  214   b  are each eight-tooth sprockets and central sprocket  214   c  is a four-tooth sprocket. 
     As shown, outer sprockets  214   a ,  214   b  are spaced apart so that they are aligned with the side strap bosses  37 ,  38  and the vertical sprocket openings  59  along each side of the chain  205 . Also, in this example, central sprocket  214   c  is positioned so that the teeth  112  of central sprocket  214   c  are received in the gap between adjacent universal connector assemblies  40  and engage a universal connector assembly  40 . In the illustrated embodiment, as conveyor chain  205  wraps around driving member  200 , each sprocket tooth  112  of the outer sprockets  214   a ,  214   b  engages a side strap boss  37 ,  38  or the base  56  of a flight arm  53 ,  54  via a vertical sprocket opening  59  along both sides of the chain  205 . At the same time, each sprocket tooth  112  of central sprocket  214   c  engages a universal connector assembly  40  along the central longitudinal axis of the chain  205 . The sprocket teeth of central sprocket  214   c  engage grooves  45 ,  47  formed in universal connector assembly  40 . As shown, a first sprocket tooth  112  of an outer sprocket  214   a ,  214   b  may abut a first side strap boss  37 , while a second sprocket tooth  112  of an outer sprocket  214   a ,  214   b  may abut a second side strap boss  38 , while a third tooth  112  of an outer sprocket  214   a ,  214   b  may be received by and extend at least partially through a vertical sprocket opening  59 . At the same time, a first sprocket tooth  112  of central sprocket  214   c  may be received by and extend at least partially through an opening between a first pair of adjacent universal connector assemblies  40 , while a second sprocket tooth  112  of central sprocket  214   c  may be received by and extend at least partially through an opening between a second pair of adjacent universal connector assemblies  40 . Although not shown in  FIG. 14 , additional sprocket teeth  112  on outer the outer sprockets  214   a ,  214   b  may engage additional side strap bosses and vertical sprocket openings and additional sprocket teeth  112  on central sprocket  214   c  may engage additional openings between additional pairs of adjacent universal connector assemblies  40  as the chain wraps around the driving member  200 . In the illustrated embodiment, the sprocket teeth  112  do not directly engage or contact connecting pins  31 ,  32  or flight pins  51 ,  52 . Because the points of engagement between conveyor chain  205  and sprocket teeth  112  (i.e. side strap bosses  37 ,  38 , flight arm bases  56 , and universal connector assemblies  40 ) are thicker than the points of engagement in some prior art conveyor chains (such as chains where sprocket teeth directly engage bearing pins in the chain), conveyor chain  205  may provide improved chain life and strength. 
     In an alternate embodiment (not shown), the driving member may comprise a single sprocket, such as central sprocket  214   c  described above. In such an embodiment, the single sprocket may be positioned and configured to engage the chain by having the teeth of the sprocket received between adjacent universal connector assemblies, similar to the central sprocket  214   c  described above. 
       FIG. 18  illustrates an alternative embodiment of the invention, wherein a solid articulating connector  304  is utilized to replace some or all of the universal connector assemblies  40 , along the length of the chain  300 .  FIG. 24  illustrates another embodiment  302 , wherein all of the universal connector assemblies  40  are replaced by the solid articulating connector  304 . The articulating connector  304  is in the form of a solid single piece or body that is formed of an appropriate steel material, such as a carbon alloy steel. In the chains of  FIGS. 18 and 24 , like reference numerals will be utilized for those parts and portions of the chain previously discussed herein. Specifically, chains  300  and  302  include a plurality of flight arm assemblies  50  connected with side link assemblies  35 , with appropriate connectors. In the embodiment illustrated in  FIG. 18 , every other universal connector is a single piece solid articulating connector  304  of the invention, along with other universal connector assemblies  40 . As discussed herein, the chain can be driven by a suitable drive mechanism  200 , including either a dual sprocket arrangement, or a triple sprocket arrangement, for example (See  FIG. 14 ). 
     Referring to  FIGS. 18 and 19 , universal connector  304  is coupled with each of the respective side link assemblies and flight arm assemblies by respective flight pins  51 ,  52 , and connecting pins  31 ,  32 . The connectors  304  are captured between the side straps  33 ,  34 , and flight arms  53 ,  54 . The pins pass through apertures  306 ,  308  formed in the connector  304  to extend transversely, or from side to side in the body, as illustrated in  FIGS. 20-22 . The apertures  306 ,  308  extend laterally or from side to side in the articulating connector, and are dimensioned with respect to the diameter of the pins, and are configured so as to provide movement and articulation of the pins within the connector, and thus, provide articulation of the chain  300 ,  302 , as illustrated in  FIGS. 18-20 and 24 . In one embodiment, the apertures  306 ,  308  are dimensional in length L, with respect to the pin to be larger than the diameter D of a pin ( 31 ,  32 ,  51 ,  52 ) length so as to provide articulation in the path of chain movement. Generally, the height dimension H will be similar to the pin diameter D, with some nominal clearance. In one exemplary embodiment, the length L may be up to three times (3×) diameter D in length, while the height may be around D with a +0.015 inch clearance or more. 
     Turning to  FIGS. 21-23 , unique solid articulating connector  304  of the invention operates similar to a universal connector but provides greater chain strength and eliminates the need for the more complicated universal connector assembly  40 . As such, this eliminates the need for universal link  42 , the connector link  43 , as well as the various universal pins  41 . As such, the articulating connector  304  reduces the complexity of the chain, increases the chain strength and also reduces potential breakage points associated with a universal connector assembly. Furthermore, the solid single piece articulating universal connectors  304  weigh around 2-3 pounds less than a typical universal assembly  40 , and thus, can significantly reduce the weight of the chain by, on average, 200 pounds, for a typical chain length. The articulating connector  304  is uniquely formed and shaped with specific curved and profiled apertures and surfaces to provide the articulation and universal movement of the chains, as desired, and as necessary for their proper operation. In one embodiment of the invention, the connector may be configured to provide an articulation angle in the range from 0°-150°. 
     Turning to  FIGS. 21-23 , the articulating connector  304  has a unique configuration and shape to provide the desired universal movement, articulation, and robustness of the solid articulating connector, in accordance with the invention. The solid articulating connector is shaped so as to provide the desired articulation, as well as to allow the necessary clearance around portions of the drive mechanism, such as a sprocket shaft and/or tail shaft roller, as discussed herein. Therefore, the invention provides a solid single piece articulating connector with a profile design to allow articulation of a conveyor chain on bulk material conveyor equipment. The solid articulating connector profile is dimensioned, and can be modified, within a range to allow essentially no articulation for straight running conveyors, or up to 150° total articulation for a single articulating connector around a pin, such as pins  51 ,  52 , and pins  31  and  32 , as shown in  FIGS. 18-20 . 
     Turning to  FIG. 21 , a top cross-sectional view of a solid articulating connector  304  is illustrated, showing apertures  306 ,  308  therein at both ends of the connector. The apertures are in the form of uniquely configured and profiled holes that will have a diameter D dimension reflective of the size of the various flight pins, or connecting pins handled by connector  304 . The connector is dimensioned to have a block height H b  and a block width W b . Block height H b  may be in the range of a hole diameter plus 0.125 inches (hole D+0.125) to (3× hole D). The hole diameter D might be in the range of 0.25 inches-2.50 inches. As such, a suitable block height H b  might be from 0.375 inches-7.5 inches. In one embodiment, the H b =2.25 inches. The width W b  might be in the range of 1 inch-5 inches. In one embodiment, the W b =2.25 inches. 
     Articulating connector  304  may be dimensioned to have a suitable pitch P of 1 inch-10 inches. In one embodiment, the pitch P is around 3.63 inches. The embodiments of the articulating connector  304  illustrated also has a center section  310  having a certain material thickness. The center section spans between the top and bottom walls  311 ,  313  of the connector. The center section  310  might also be eliminated. The material thickness of the center section  310  (Dimension C in  FIG. 22 ) might be anywhere from 0 inches up to 9.75 inches, which would reflect an upper limit of approximately the pitch P minus the hole diameter D. In one embodiment, such thickness is around 0.75 inches. In the center section  310 , because of the radiused shape of holes of apertures  306 ,  308 , the thickness will vary along the height of section  310 . Furthermore, the connector includes a wall thickness T that may be from approximately 0.0625 inches up to 2.5 inches. This reflects a wall thickness T that is from 0.0625 inches up to one-half of the block height H minus the hole diameter D ((block height H−hole diameter D)/2). In one embodiment, the thickness T=0.55 inches. 
     In accordance with one aspect of the solid articulating connector  304  of the invention, the side connector surfaces are appropriately curved and profiled inwardly to provide the desired articulation, as well as operation with the drive mechanism driving a chain. To that end, the solid articulating connector  304  includes contoured profiles in the sides, top, and bottom of the connector. Referring to  FIG. 21 , the sides  315 ,  317  of the connector have an exterior profile that is contoured with an indent or inwardly profiled surface  312  that is dimensioned in depth D 1  and width W 1 , on both sides of the connector. The inwardly profiled surfaces  312  provide a suitable articulation angle A, as illustrated in  FIG. 20 . The profiled surfaces  312  are configured to receive a portion of the flight arm assembly or a portion of the side link assembly to provide articulation of the chain. More specifically, as illustrated in  FIGS. 19 and 20 , the profiled surfaces  312  are configured to receive an end portion  360  of side straps  33 ,  34 , or to receive an end portion  362  of a base  56  for providing articulation of the flight arm assembly and side link assembly with respect to each other and articulation of the conveyor chain along its path of travel  364 , as shown in  FIG. 19 . The profiled surfaces  312  may be comprised of suitable angled or chamfered surfaces, or curved/radiused surfaces to allow proper articulation, the depth D 1  and the width W 1  and radius R 1  provide the desired articulation, as shown in  FIGS. 19 and 20 . To that end, in one embodiment of the invention, the depth D 1  might be anywhere from 0 inches-2.5 inches, or from essentially 0 inches-one-half of block width W b . As may be understood by a person of ordinary skill in the art, a profile surface  312  having a depth D 1  of 0 inches would essentially be a straight block, without a particular side profile. The width W 1  might be anywhere from 0 inches-12.5 inches, or essentially from 0 inches to the dimension of the pitch plus the hole diameter (pitch P+hole D). 
     In one embodiment, the surface is dimensioned with D 1 =0.25 inches, W 1 =2.18 inches, and an R 1 =2.50 inches. The edges  319  might form radiused transition edges at a radius of around 0.75 inches in one embodiment. Referring to  FIG. 21 , the overall block length L b  might be in the range of 1.25 inches-15 inches. Generally, the block length L b  might be in the range of 1 inches plus the hole diameter D 1 , up to the pitch P dimension plus the hole diameter D, plus two times the wall thickness T ((pitch P+hole D+(2× wall thickness T)). In one embodiment, the L b =5.88 inches. 
     Referring again to  FIG. 21 , solid articulating connector  304  includes opposing ends of the connector that include profiled end surfaces  316  that work in tandem with the exterior side profiled surfaces  312  to provide the articulation of connector  304 . The profiled surfaces  316  may be suitably chamfered, or may be outwardly radiused, or could be in the form of a sharp corner. In  FIG. 21 , a radiused edge or surface is shown, and may have a radius range of 0 inches (sharp corner) to 5 inches, or generally from 0−(wall thickness T+hole D). In one embodiment, the radius is around 0.25 inches. The profiled surfaces  316  engage a portion of either the side straps  33 ,  34 , or the base  56 , as shown in  FIG. 19 , when the chain articulates. As seen in  FIG. 19 , the profiled surfaces  312  and profiled surfaces  316  are engaged on opposite sides of the chain during articulation. 
     As seen in  FIGS. 21 and 22 , each of the holes or apertures  306 ,  308  is configured to receive one of the noted pins ( 31 ,  32 ,  51 ,  52 ) that couple the connector to various side link assemblies or flight arm assemblies. In accordance with one aspect of the invention, each of the aperture openings includes a pin hole profiled surface that forms a curved or radiused surface along an outer surface, as indicated by reference numeral  320  in the figures, and along an inner surface  321 . The profiled or curved surfaces  320 ,  321  of apertures  306 ,  308 , allow a smooth articulation between each of the various pins, and the solid articulating connector  304 . The surfaces  320 ,  321  open up the holes  306  and  308  to have a diameter that is equal to the hole size or larger. The diameter D is reflective of the diameter of a pin  32 ,  51  in the solid articulating connector  304  (See  FIG. 20 ). Surfaces  320 ,  321  also follows a radiused profile that is sized based on the articulation angle that is desired, such as from 0-150° articulation, as illustrated in articulation angle A of  FIG. 21 . The profiled or curved surface  320  allows the solid articulating connector to roll on the pin during articulation. In one embodiment, the profiled surfaces  320 ,  321  reflect a radius of around 1.25 inches. The ends of the solid articulating connector might also be appropriately chamfered at an angle A 2  of around 5 degrees, or suitable draft angle. The profiled surfaces  320 , which will bear most of the load from the pins  31 ,  32 ,  51 ,  52 , may be induction hardened to have a greater hardness. The surfaces  320  of the apertures  306 ,  308  are hardened at a specific depth around the apertures to a greater hardness rating than the rest of the link. For example, while the articulating connector might have a hardness of around 40-44 on the Rockwell C Scale (Rc), the surfaces  320  might be induction hardened to have a hardness rating of around 50-54 Rc. In accordance with one embodiment of the invention, the hardness may be induced to a depth D of ⅛ inch to 3/16 inches deep around the surfaces  320  and extending through the apertures from side to side. 
     Turning to  FIG. 22 , the connector  304  is profiled inwardly along the top and bottom surfaces in accordance with one aspect of the invention, to provide clearance and articulation around the rollers of the drive shaft and tail shaft. For example, the top and bottom connector surfaces include inwardly profiled surfaces  323 ,  325  therein that allow clearance and articulation around the sprocket foot shaft and/or tail shaft roller. As illustrated, the profiled surfaces are shown to have a depth of D 2 , and a width of W 2  and a radius R 2 , and may be comprised of cooperative surfaces to form the profile, or curve, which will provide a clearance of the rollers, as the articulating connectors move over the rollers. A suitable profile for the depth D 2  would be from 0 to 3.75 inches, or roughly 0-one-half the block height H b . The width dimension W 2  might be in the range of 0-12.5 inches, or from 0 to (pitch+hole diameter). As would be understood by a person of ordinary skill in the art, if a depth and width of 0 inches would essentially refer to a block that does not have the noted clearance profile, as illustrated in  FIG. 22 . Other embodiments would have the desirable angled chamfer or radius curves for providing the profile illustrated in  FIG. 22  along the top and bottom of the connector  304 . In one embodiment, the profiled surface has D 2 =0.25 inches, W 2 =2.13 inches, and R 2 =2.40 inches. Corner edge surfaces  327  have a radius of around 0.75 inches. 
     The aperture diameter D might be in the range of 0.25-2.5 inches to define the curved inner surfaces from top to bottom of apertures  306 ,  308  to accommodate the pins. In one embodiment D=1.14 inches. 
       FIG. 23  illustrates an alternative embodiment of the invention, wherein the exterior side surfaces  324  of the sides of the solid articulating connector on either end of the connector and either end profiled surfaces  312  are also profiled. Specifically, surfaces  324  are chamfered or radiused to, or otherwise profiled outwardly from, the connector sides to increase the effective block width W b . Specifically, as shown by solid articulating connector  304   a  in  FIG. 23 , side surfaces  324  are profiled with a suitable radius or chamfer to provide an effective widening of the block width W b  outwardly from the ends of solid articulating connector  304   a . Generally, the top profile would then more aptly resemble a “bow tie” shape, as illustrated in  FIG. 23 . For example, an 11° chamfer angle A c  might be provided on opposite ends of the point defining the widest W b . The chamfer works with radiused surfaces reflect by R 3  to form a W b =2.44 in one embodiment. Connector  304   a  may have aperture dimensions and profiling, as well as top and bottom dimensions shown in  FIG. 22 . 
     Referring to  FIG. 20 , providing a profiled, radiused, or chamfered surface, and thus, a wider block width W b  at the surfaces  324 , as illustrated in  FIG. 23 , will add additional material on the side, and thus, take up space or slack in between the various side straps and/or flight arms in the chain. As shown in  FIGS. 19 and 20 , when the chain articulates, uniquely profiled openings  306  and  308 , and the various profiled surfaces  312 ,  323 ,  325 ,  320 ,  321 ,  316  provide movement of the solid articulating connector  304  around the pins  32  and  51 . However, when the chain is straight, as shown in portions of  FIG. 18 , there may be spacing between the opposing side straps or flight arms that provides some slack between the sides of the solid articulating connector  304  and those components of the chain. By providing a profiled, radiused, or chamfered surface  324 , as shown in  FIG. 23 , such slack may be addressed, while still providing suitable articulation of the link assemblies, with respect to the solid articulating connector  304 . The side profiled surfaces  312  provide clearance to prevent interference with the flights and the base or head  56  of the flights, as shown in  FIG. 20 . Profiled surfaces  320 ,  321  provide smooth articulation between the pins and the connector. Profiled surfaces  316  prevent interference between the connector and opposing flight bases  56 . The profiled surfaces  323 ,  325  provide clearance around sprocket rollers. 
       FIG. 24  illustrates another embodiment of the chain, wherein the solid articulating connectors  304  are utilized between each of the link assemblies in the chain  302 , rather than every other one, as illustrated in  FIG. 18 . Thus,  FIG. 24  provides a chain that is even lighter, and which still maintains the ability to articulate as desired, similar to the articulation provided by the universal connector assembly, as utilized in other embodiments. Thus, chain  24  eliminates any of the drawbacks associated with the universal connector assemblies  40 , by utilizing only the invented solid single-piece articulating connector  304  of the invention. 
       FIGS. 25 and 26  illustrate additional embodiments of the invention.  FIG. 25  illustrates a solid articulating connector  304   b . The solid articulating connector  304   b  is somewhat similarly configured and shaped with various profiled and contoured surfaces, as the articulating connector  304  is illustrated in  FIGS. 20-22 , for example, although it might also be made to incorporate the design of connector  304   a  as illustrated in  FIG. 23 . The solid articulating connector  304   b  also includes raised ribs  350  at the end of the articulating connector. The raised ribs, on opposite sides of the connector, and along the top and bottom surface (partially) essentially form or define a grooved surface or groove  352  in each end of the connector. The ribs provide added strength at the ends of the articulating connector. The defined groove  352  is configured for sprocket alignment, such as when a third sprocket is utilized to drive the chain. 
     Referring to  FIG. 26 , an embodiment of the chain is illustrated utilizing the solid articulating connector  304   b , as illustrated in  FIG. 25 . The drive mechanism is a triple drive sprocket  200  that incorporates three sprockets. The outer sprockets and the teeth thereof engage sections of the flight arm assemblies  50  and side link assemblies  30 , as shown. A center sprocket engages the chain at each of the solid articulating connectors  304   b , as shown in  FIG. 26 . More specifically, as illustrated, the third sprocket or center sprocket has teeth which engage the various grooves  352  of the solid articulating links  304   b.    
     In another embodiment of the invention, a chain design provides significant noise reduction, while maintaining proper movement and spacing of the various links. In such an embodiment, as illustrated in  FIG. 27 , the various solid articulating connectors  304 ,  304   a ,  304   b  of a chain, incorporate flexible spacers  350  on either side of the solid articulating connector. More specifically, the spacers  350  are positioned between an appropriate connector (e.g.,  304 ,  304   a ,  304   b ) and the bases  56  of a flight arm in an assembly, or the side straps  33 ,  34  of an assembly. As illustrated in  FIG. 27 , an exemplary embodiment incorporates a spacer  350  between the solid articulating connector and each of the flight arm or side link assemblies. That is, the spacers are positioned on each side of the articulating connects. 
     The flexible spacer  350  may be made of a suitably soft material for providing flexibility and cushioning, such as urethane, to provide noise reduction between the solid articulating connector and the assemblies that make up the links of the chain. Furthermore, the spacers provide a suitable distance or spacing between the solid articulating connector and the various chain components so as to maintain a specific alignment and spacing of the various links while the chain moves and articulates, and is driven by the sprockets. In one exemplary embodiment, the spacer would generally be a circular or washer-type component. A center opening is formed therein for passage of flight pins or connecting pins, and has an inner diameter of around 1.125 inches. The outer diameter might be around 2 inches. Of course, other material or size embodiments might be utilized, in accordance with the invention, to maintain the desired noise reduction and spacing. In one exemplary embodiment, the thickness of the spacer  35  is around 0.094 inches. Of course, that dimension might also be varied, and still achieve the desired noise reduction and spacing of the invention. 
       FIG. 28  illustrates another alternative embodiment of the invention, wherein a solid articulating connector  404  is utilized to replace some or all of the universal connector assemblies  40 , along the length of the chain  402 .  FIG. 28  illustrates an embodiment  402 , where each universal assembly is replaced with connectors  404 . As discussed above for connector  304 , the articulating connector  404  is in the form of a solid single piece or body that is formed of an appropriate steel material, such as a carbon alloy steel. In the chains of  FIGS. 28, 32, and 33 , like reference numerals will be utilized for those parts and portions of the chain previously discussed herein. Specifically, chain  402  includes a plurality of flight arm assemblies  50  connected with side link assemblies  30 , with appropriate connectors. In the embodiment illustrated in  FIG. 28 , each universal connector is a single piece solid articulating connector  404  of the invention. As discussed herein, the chain can be driven by a suitable drive mechanism  200 , including either a dual sprocket arrangement, or a triple sprocket arrangement, for example (See  FIG. 14 ). 
     Referring to  FIGS. 28 and 32 , universal connector  404  is coupled with each of the respective side link assemblies and flight arm assemblies by respective flight pins  51 ,  52 , and connecting pins  31 ,  32 . The connectors  404  are captured between the side straps  33 ,  34 , and flight arms  53 ,  54 . The pins pass through apertures  406 ,  408  formed in the connector  404 , to extend transversely, or from side to side, in the solid body, as illustrated in  FIGS. 29-31 . The apertures  406 ,  408  extend laterally or from side to side in the articulating connector  404 , and are dimensioned with respect to the diameter of the pins. The apertures  406 ,  408  are configured so as to provide movement and articulation of the pins within the connector, and thus, provide articulation of the chain  402 , as illustrated in  FIGS. 28, 32 and 33 . In one embodiment, the apertures  406 ,  408  are dimensioned in length L, with respect to the pin to be larger than the diameter D of a pin ( 31 ,  32 ,  51 ,  52 ) length so as to provide articulation in the path of chain movement (See  FIG. 30 ). Generally, the height dimension H will be similar to the pin diameter D, with some nominal clearance. In one exemplary embodiment, the length L may be up to three times (3×) diameter D in length, while the height may be around D with a +0.015 inch clearance or more. 
     Turning to  FIGS. 29-31 , unique solid articulating connector  404  of the invention operates similar to a connector  304 , and provides greater chain strength and eliminates the need for the more complicated universal connector assembly  40 . As such, the articulating connector  404  also reduces the complexity of the chain, increases the chain strength and also reduces potential breakage points associated with a universal connector assembly. Furthermore, the solid single articulating universal connectors  404  weigh around 2-3 pounds less than a typical universal assembly  40 , and thus, can significantly reduce the weight of the chain by, on average, 200 pounds, for a typical chain length. The articulating connector  404  is also uniquely formed and shaped with specific curved and profiled apertures and surfaces, as well as wing components and some flat surfaces, to provide the articulation and universal movement of the chains, as desired, and as necessary for their proper operation. In one embodiment of the invention, the connector may be configured to provide an articulation angle in the range from 0°-150°. Turning to  FIGS. 29-31 , the articulating connector  404  has a unique configuration and shape to provide the desired universal movement, articulation, and robustness of the solid articulating connector, in accordance with the invention. The solid articulating connector is shaped so as to provide the desired articulation, as well as to allow the necessary clearance around portions of the drive mechanism, such as a sprocket shaft and/or tail shaft roller, as discussed herein. Furthermore, the connector  404  is shaped to reduce noise of the chain as it runs over the tail roller. Therefore, the invention provides a solid single piece articulating connector with a profile design to allow articulation of a conveyor chain on bulk material conveyor equipment. The solid articulating connector profile is dimensioned, and can be modified, within a range to allow essentially no articulation for straight running conveyors, or up to 150° total articulation for a single articulating connector around a pin, such as pins  51 ,  52 , and pins  31  and  32 , as shown in  FIGS. 28, 32-33 . 
       FIG. 29  is a perspective view of a solid articulating connector  404 , in accordance with one embodiment of the invention. Connector  404  incorporates a solid body that incorporates top and bottom connector surfaces  423 ,  425  that have portions that are essentially flat, or are flattened, rather than contoured, as in the embodiment of connector  304 . While most of the top and bottom surfaces are illustrated as flattened, there may still be portions of those surfaces that have some contours, such as portions, near the end of the connector body. Furthermore, connector  404  incorporates wing components, or wings  450 , that extend from the connector  404 , and form part of the top and bottom surfaces  423  and  425 . The wings  450  extend from both sides of the connector  404 , at the top and bottom surfaces  423 ,  425 , as illustrated in  FIG. 29 . In the embodiment of  FIG. 29 , a pair or wings are positioned on the top of the connector proximate to top surface  423 , and a pair of wings is also positioned along the bottom of the connector proximate the bottom surface  425 . In an alternative embodiment of the invention, as illustrated in  FIG. 29 , the pair of wings  450  might only be positioned on one of the top or the bottom of the connector, and proximate a top or bottom surface. Portions of the surfaces  453  of the wings  450  might also be flattened similar to the flattened surfaces  423 ,  425  to form flattened top and bottom surfaces to the connector body. The wings are positioned along the length L B  of the connector body, generally at the middle of the connector body. Referring to  FIG. 30 , the wings might be positioned to coincide with the center section  410  of the connector. 
     In accordance with one aspect of the invention, the combination of the wings  450  and the flattened top and bottom surfaces  423  and  425  provide a wider effective connector  404  at the top and bottom that does not have profiled top and bottom surfaces. The connector  404  contacts the surfaces and rollers of the drive system for chain  402 . The effectively wider connector rides flat on various chain rollers, such as the tail roller, similar to the side straps  33 ,  34 , and the flight arms  53 ,  54 . In that way, as the overall chain progresses over a roller, such as the tail roller, the solid connector  404  does not sink onto the tail roller like a connector that has profiled top and bottom surfaces. That is, the wings  450  effectively widen the profile of the solid connector  404 , and in combination with the flattened top and bottom surfaces  423 ,  425 , provides a solid connector  404  that has a profile along the top and bottom surfaces closer to the top and bottom profile of a side strap of the conveyor chain. The solid connector  404  thus, prevents a change in the profile or contour between the various side straps, flight arms, and solid connectors  404 , as the chain  402  moves over the rollers, and thus, prevents the chain from bouncing, or going up and down, as each of the various link elements of the chain pass over a roller. This, in turn, keeps the chain smoothly on the roller, and reduces the noise generated as the chain passes over a roller. 
     Turning to  FIGS. 30 and 31 , a top cross-sectional view and side view of a solid articulating connector  404  are illustrated, showing apertures  406 ,  408  therein at both ends of the connector. The solid articulating connector  404  has similarities to connector  304  in construction, which will be described. The apertures are in the form of uniquely configured and profiled holes that will have a diameter D dimension reflective of the size of the various flight pins, or connecting pins handled by connector  404 . The connector is dimensioned to have a block height H b  and a block width W b . Block height H b  may be in the range of a hole diameter plus 0.125 inches (hole D+0.125) to (3× hole D). The hole diameter D might be in the range of 0.25 inches-2.50 inches. As such, a suitable block height H b  might be from 0.375 inches-7.5 inches. In one embodiment, the H b  is around 2.25 inches. The width W b  might be in the range of 1 inch-5 inches. In one embodiment, the W b  is around 2.25 inches. 
     Articulating connector  404  may be dimensioned to have a suitable pitch P of 1 inch-10 inches. In one embodiment, the pitch P is around 3.50 inches. The embodiment of the articulating connector  404  illustrated also has a center section  410  having a certain material thickness. The center section spans between the top and bottom walls  411 ,  413  of the connector. The center section  410  might also be eliminated. The material thickness of the center section  410  (Dimension C in  FIG. 31 ) might be anywhere from 0 inches up to 9.75 inches, which would reflect an upper limit of approximately the pitch P minus the hole diameter D. In one embodiment, such thickness is around 0.75 inches. In the center section  410 , because of the radiused shape of holes of apertures  406 ,  408 , the thickness will vary along the height of section  410 . Furthermore, the connector includes a wall thickness T that may be from approximately 0.0625 inches up to 2.5 inches. This reflects a wall thickness T that is from 0.0625 inches up to one-half of the block height H minus the hole diameter D ((block height H−hole diameter D)/2). In one embodiment, the thickness T is around 0.55 inches. 
     In accordance with one aspect of the solid articulating connector  404  of the invention, the side connector surfaces  412  between the wings  450  on the top surface  423  and the wings on the bottom surface  425  are appropriately curved and profiled inwardly to provide the desired articulation, as well as operation with the drive mechanism driving the chain. To that end, the solid articulating connector  404  includes contoured profiles in the sides of the connector. Referring to  FIG. 30 , the sides  415 ,  417  of the connector have an exterior profile that is contoured with an indent or inwardly profiled surface  412  at the center of the connector between the wings  450  that is dimensioned in depth D 1  and width W 1 , on both sides of the connector and between an upper set of wings and a lower set of wings. The inwardly profiled surfaces  412 , in combination with the wings will provide a suitable articulation angle A, as illustrated in  FIG. 33 . The profiled surfaces  412  are configured to receive a portion of the flight arm assembly when the chain bends or a portion of the side link assembly to provide articulation of the chain. More specifically, as illustrated in  FIGS. 32 and 33 , the profiled surfaces  412  are configured to receive an end portion  460  of side straps  33 ,  34 , or to receive an end portion  462  of a base  56  for providing articulation of the flight arm assembly and side link assembly with respect to each other and articulation of the conveyor chain along its path of travel  464 , as shown in  FIG. 32 . The profiled surfaces  412  may be comprised of suitable angled or chamfered surfaces, or curved/radiused surfaces to allow proper articulation, the depth D 1  and the width W 1  and radius R 1  provide the desired articulation, as shown in  FIGS. 32 and 33 . To that end, in one embodiment of the invention, the depth D 1  might be anywhere from 0 inches-2.5 inches, or from essentially 0 inches-one-half of block width W b . As may be understood by a person of ordinary skill in the art, a profile surface  412  having a depth D 1  of 0 inches would essentially be a straight block, without a particular side profile. The width W 1  might be anywhere from 0 inches-12.5 inches, or essentially from 0 inches to the dimension of the pitch plus the hole diameter (pitch P+hole D). 
     In one embodiment, the surface is dimensioned with D 1  of around 0.25 inches, W 1  of around 1.5 inches, and an R 1  of around 3.00 inches. The edges  419  of surface  412  might form radiused transition edges at a radius of around 0.75 inches in one embodiment. Referring to  FIG. 30  the overall block length L b  might be in the range of 1.25 inches-15 inches. Generally, similar to connector  304  the block length L b  might be in the range of 1 inches plus the hole diameter D 1 , up to the pitch P dimension plus the hole diameter D, plus two times the wall thickness T ((pitch P+hole D+(2× wall thickness T)). In one embodiment, the L b  is around 5.827 inches. 
     Referring again to  FIG. 30 , solid articulating connector  404  includes opposing ends of the connector that include profiled end surfaces  416  that work in tandem with the exterior side profiled surfaces  412  to provide the articulation of connector  404 . The profiled surfaces  416  may be suitably chamfered, or may be outwardly radiused, or could be in the form of a sharp corner. In  FIG. 30 , a radiused edge or surface is shown, and may have a radius range of 0 inches (sharp corner) to 5 inches, or generally from 0−(wall thickness T+hole D). In one embodiment, the radius is around 0.25 inches. The profiled surfaces  416  engage a portion of either the side straps  33 ,  34 , or the base  56 , as shown in  FIG. 32 , when the chain articulates. As seen in  FIG. 32 , the profiled surfaces  412  and profiled surfaces  416  are engaged on opposite sides of the chain during articulation. 
     As seen in  FIGS. 30 and 31 , each of the holes or apertures  406 ,  408  is configured to receive one of the noted pins ( 31 ,  32 ,  51 ,  52 ) that couple the connector to various side link assemblies or flight arm assemblies. In accordance with one aspect of the invention, each of the aperture openings includes a pin hole profiled surface that forms a curved or radiused surface along an outer surface, as indicated by reference numeral  420  in the figures, and along an inner surface  421 . The profiled or curved surfaces  420 ,  421  of apertures  406 ,  408 , allow a smooth articulation between each of the various pins, and the solid articulating connector  404 . The surfaces  420 ,  421  open up the holes  406  and  408  to have a diameter that is equal to the hole size or larger. The diameter D is reflective of the diameter of a pin  32 ,  51  in the solid articulating connector  404  (See  FIG. 31 ). Surfaces  420 ,  421  also follows a radiused profile that is sized based on the articulation angle that is desired, such as from 0-150° articulation, as illustrated in articulation angle A of  FIG. 33 . The profiled or curved surface  420  allows the solid articulating connector to roll on the pin during articulation. In one embodiment, the profiled surfaces  420 ,  421  reflect a radius of around 1.25 inches. The ends  416  of the solid articulating connector might also be appropriately chamfered at an angle A 2  of around 5 degrees, or suitable draft angle (See  FIG. 30 ). The profiled surfaces  420 , which will bear most of the load from the pins  31 ,  32 ,  51 ,  52 , may be induction hardened to have a greater hardness. The surfaces  420  of the apertures  406 ,  408  are hardened at a specific depth around the apertures to a greater hardness rating than the rest of the link. For example, while the articulating connector might have a hardness of around 40-44 on the Rockwell C Scale (Rc), the surfaces  420  might be induction hardened to have a hardness rating of around 50-54 Rc. In accordance with one embodiment of the invention, the hardness may be induced to a depth D of ⅛ inch to 3/16 inches deep around the surfaces  420  and extending through the apertures from side to side. 
     Turning to  FIG. 31 , the connector  404  has a generally flat (i.e. non-radiused) top and bottom surfaces that include the wings  450  in accordance with one aspect of the invention, to provide smooth travel around the tail roller. 
     Referring to  FIG. 34 , the wings  450  may provide an overall effective width of the connector  404  W w  in the range of 1.0 to 6.0 inches. In one embodiment, W w  might be around 3.5 inches. The wings may have a thickness T w  in the range of 0.25 to 1.5 inches. In one embodiment, T w  is around 0.83 inches. Also, as illustrated in  FIG. 34 , the wings, while flat on the upper and lower surfaces  423 ,  425 , may be angled with respect to each other at the surfaces  460 , in an angular range A w  from 0 degrees to 90 degrees. In one embodiment of the invention, A w  is around 10 degrees. 
     Referring to  FIG. 35 , the wings  450  may be formed to have an overall effective width W w  in the range of 0 inches to L B /3 inches. In one embodiment, W w  is around 1.25 inches. The side surfaces  451  of the wings  450  might also be tapered in an angle with respect to each other A s  in the range of 0 degrees to 150 degrees. The wings  450  cannot be made too wide with respect to dimension W w  because articulation is necessary between the various links, as illustrated in the  FIGS. 32, 33 . Generally, because the wings  450  are located at the top and bottom surfaces  423 ,  425  of connector  404 , and are kept somewhat thinner in their overall side profile dimension T w  the end portions  460 ,  462  of the various links which engage connector  404  will pass somewhat under the wings during articulation, as illustrated in  FIGS. 32 and 33 , to otherwise engage the profiled surfaces  412 . However, there may be some engagement of the wings  450  with the end portions  460 ,  462  of each of the respective links that are coupled to connector  404 . 
       FIG. 28  illustrates an embodiment of the chain, wherein the solid articulating connectors  404  are utilized between each of the link assemblies in the chain  402 . However, similar to  FIG. 18 , the connectors  404  might be used at every other universal connector position. 
     In another embodiment of the invention, a chain design provides significant noise reduction, while maintaining proper movement and spacing of the various links, and, as shown in  FIG. 27 , the various solid articulating connectors may incorporate flexible spacers  350  on either side of the solid articulating connector. Such spaces might also be used with the connectors  404  described herein. 
     The various conveyor chains disclosed herein may comprise an even pitch along substantially the entire length of the conveyor chain, although this is not required. The pitch may comprise the distance between adjacent connecting pins  31 ,  32  and flight pins  51 ,  52 . In one embodiment, the pitch may comprise about 3½ inches, although any suitable pitch may be used depending on the particular application. By way of example only, the pitch may also range from about 1 inch to about 5 inches in length, or more particularly from about 2½ inches to about 4½ inches in length. A conveyor chain with an even pitch may provide for an increased number of sprocket teeth engaged with the chain and may allow for the use of a driving member that comprises two or more individual sprockets. 
     The present chain, as described and illustrated herein, provides a particularly robust and wear resistant chain that improves upon the chain design provided by the flight assemblies and universal connector assemblies. The inventive chain allows more sprocket engagement and thus provides better inset chain flow over a foot shaft with more teeth engaged to carry the chain load. Furthermore, the chain provides an improved and higher breaking strength. Because the dual sprockets drive in the flight arm attachment apertures and on the side strap bosses, the chain eliminates significant pin wear and failure caused from pin breakage. Also, the solid articulating connectors provide increased flight articulation in the movement of the chain. Still further, the chain provides noise reduction and maintains a desired spacing of the various links for proper operation. 
     It should be appreciated that the various components may be comprised of any suitable material known in the art that exhibits the requisite strength and durability characteristics based on the intended application of the chain. By way of example only, the various components may comprise forged steel, cast steel, spring steel, composite steel, plastic, other suitable materials and combinations thereof. Each of the components may comprise the same material, or alternatively, different components may comprise different materials. In addition, by way of example only the flight arms  53 ,  54  or any other suitable components, may be made of composite steel and plastic, urethane, or other material that can reduce noise levels during operation, although this is not required. 
     Having shown and described various embodiments of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, geometrics, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the present invention should be considered in terms of the following claims and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.