Patent Description:
Conveyor systems have long been used to assist in the transport of materials from one location to another, in particular with respect to heavy and cumbersome items. The use of conveyor systems in assembly lines is well documented, with perhaps Henry Ford being the most famous proponent of the technology of the <NUM>th century.

Conveyors come in a variety of configurations, suiting a wide array of implementations. Belt conveyors in particular have been widely adopted due to their wide versatility and adaptability. For example, belt conveyors are commonly used in the warehousing, manufacturing, and mining sectors. More recently, belt conveyors have found application in the automotive industry, in particular with respect to automated car wash stations.

Some car washes employ single or synchronous dual belt conveyor systems for moving the vehicle through the wash tunnel. The belts are made from plastics and metals as these materials provide a relatively long life, and generally resist stretching and water corrosion.

The conveyor belts are supported by and travel across support decks that are conventionally made of a metal, such as steel or a steel alloy.

Over time, both the conveyor belts and the support decks wear mainly as a result of friction between the automotive vehicle-laden conveyor belts and the support decks. This wear is exacerbated by the presence of debris that is commonly removed from automotive vehicles and trapped between the conveyor belts and the support decks during the washing process. As the conveyor belts and the support decks wear, they can fatigue and/or rupture, requiring their replacement. The replacement of the conveyor belts can be particularly costly and labor-intensive.

<CIT> discloses a static transverse support element, as a replacement for conventional rollers, for supporting a lower side or an upper side of an endless conveyor belt. The support element has an upper face formed by two longitudinal parts included at an angle of <NUM> to <NUM> degrees with respect to a plane perpendicular to parallel longitudinal faces. The support element is made of polyurethane or high molecular weight polyethylene. The junction of the two parts comprises a longitudinal wear indicator of extra thickness, which may consist of an insert and have higher hardness than the rest of the support element. <CIT> discloses a conveyor system according to the preamble of claim <NUM> and a belt contact surface according to the preamble of claim <NUM>.

According to the invention, there is provided a conveyor system, comprising an endless belt mounted in a longitudinal direction through a service line, the endless belt having an upper transport portion adapted to move a wheeled structure through the service line, and a lower return portion, and a support deck positioned below the upper transport portion of the endless belt to support the endless belt, the support deck having a belt contact surface extending along a top of the support deck and in contact with the upper transport portion of the endless belt, the belt contact surface being at least partially constructed from a material that is at least partially a polymer, the belt contact surface having a set of inserts having a greater abrasion resistance than the material.

According to the invention, the belt contact surface includes a set of wear plates formed from the material. The material can be, for example, at least partially thermoplastic, polyethylene, ultra-high-molecular-weight polyethylene, or high-density polyethylene.

The conveyor system can further include a belt rinsing system including a rinsing system conduit arrangement connectable to a source of rinsing system liquid, and at least one belt rinsing arrangement, wherein each of the at least one belt rinsing arrangement includes a rinsing system dirt pass-through aperture in the support deck, over which the upper transport portion of the endless belt travels during operation, and at least one rinsing system outlet from the rinsing system conduit arrangement positioned proximate to the rinsing system dirt pass-through aperture and positioned to eject rinsing system liquid onto the endless belt upstream from a downstream edge of the rinsing system dirt pass-through aperture in order to capture at least some of the ejected liquid through the rinsing system dirt pass-through aperture.

According to the invention, each of the set of wear plates has openings in which the set of inserts are received. The inserts can have lateral sides, each of the lateral sides being oblique to a longitudinal direction of travel of the endless belt. Each of the set of inserts can have four lateral sides, each of the lateral sides forming an angle with the longitudinal direction of travel of the endless belt of between <NUM> degrees and <NUM> degrees.

Each of the set of wear plates can have a leading edge and a trailing edge dimensioned to mate with the leading edge of another of the set of wear plates, each of the leading edge and the trailing edge having oblique edge segments oblique to the longitudinal direction of travel of the endless belt and generally parallel to a closest one of the lateral sides of an adjacent one of the set of inserts.

The set of inserts can be configured in a central band extending along the longitudinal direction of travel of the endless belt, the central band extending laterally across between <NUM>% and <NUM>% of a lateral width of the set of wear plates.

The conveyor system can further comprise a belt rinsing system including a rinsing system conduit arrangement connectable to a source of rinsing system liquid, and at least one belt rinsing arrangement, wherein each of the at least one belt rinsing arrangement includes a rinsing system dirt pass-through aperture in the support deck positioned, over which the upper transport portion of the endless belt travels during operation, and at least one rinsing system outlet from the rinsing system conduit arrangement positioned proximate to the rinsing system dirt pass-through aperture and positioned to eject rinsing system liquid onto the endless belt upstream from a downstream edge of the rinsing system dirt pass-through aperture in order to capture at least some of the ejected liquid through the rinsing system dirt pass-through aperture.

The rinsing system dirt pass-through aperture can be spaced laterally from the central band.

The openings and the set of inserts can be designed so that the openings are at least partially unobstructed when the set of inserts are positioned therein, thereby defining the rinsing system dirt pass-through aperture.

The inserts and the openings can be dimensioned to inhibit upward escape of the inserts from the openings when the wear plates are positioned at the top of the support structure.

According to the invention, a compressible layer is positioned under the inserts to facilitate depression of the set of inserts relative to the set of wear plates.

According to the invention, the conveyor system has an endless belt mounted in a longitudinal direction through a service line, the endless belt having an upper transport portion adapted to move a wheeled structure through the service line, and a lower return portion, a support deck positioned below the upper transport portion of the endless belt to support the endless belt, the belt contact surface being dimensioned to extend along a top of the support deck and contact the upper transport portion of the endless belt, the belt contact surface being constructed from a material that is at least partially polymer, the belt contact surface being interspersed with inserts having a greater abrasion resistance than the material, wherein the belt contact surface comprises a set of wear plates formed from the material, and each of the set of wear plates has openings in which the set of inserts are received, and wherein a compressible layer is positioned under the inserts to facilitate depression of the set of inserts relative to the set of wear plates.

For a better understanding of the various embodiments described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings in which:.

For simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the Figures to indicate corresponding or analogous elements. In addition, numerous specific details are set forth in order to provide a thorough understanding of the embodiments described herein. However, it will be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to obscure the embodiments described herein. Also, the description is not to be considered as limiting the scope of the embodiments described herein.

Various terms used throughout the present description may be read and understood as follows, unless the context indicates otherwise: "or" as used throughout is inclusive, as though written "and/or"; singular articles and pronouns as used throughout include their plural forms, and vice versa; similarly, gendered pronouns include their counterpart pronouns so that pronouns should not be understood as limiting anything described herein to use, implementation, performance, etc. by a single gender; "exemplary" should be understood as "illustrative" or "exemplifying" and not necessarily as "preferred" over other embodiments. Further definitions for terms may be set out herein; these may apply to prior and subsequent instances of those terms, as will be understood from a reading of the present description.

Reference is made to <FIG>, which shows a service line <NUM> having a conveyor system <NUM> for moving a wheeled structure <NUM>, in accordance with an embodiment. As used herein, the term service line is not intended to be restrictive, and may encompass for example an automatic vehicle wash station (e.g., for cars, commercial trucks, etc.), a manufacturing or assembly line (e.g., for cars, trucks, non-powered mobile units, etc.) as well as a repair or detailing station (e.g., for cars, trucks, etc.). In addition, the term wheeled structure is not intended to be restrictive, and may encompass for example powered landborne vehicles (e.g., trucks, automobiles, tractors, recreational vehicles, etc.), non-powered landborne mobile units (e.g., recreational trailers, utility trailers, etc.), and airborne vehicles (e.g., airplanes, etc.).

The conveyor system <NUM> is adapted to transport a wheeled structure along a longitudinal length of the service line <NUM>. As presented in <FIG>, service line <NUM> is shown in the form of a car wash station having a wash tunnel <NUM>. Accordingly, the conveyor system <NUM> includes a service zone <NUM> within the region of the wash tunnel <NUM> through which the vehicle is transported for a wash cycle. The conveyor system <NUM> also may also include a loading zone <NUM> adjacent a tunnel entrance <NUM>, where vehicles align and initially load onto the conveyor system <NUM>.

The conveyor system <NUM> is configured as a dual-belt system comprising a pair of endless belts mounted in a longitudinal direction through the service line <NUM>. The endless belts 36a, 36b are positioned in parallel and spaced-apart relationship relative to one another through the loading and service zones <NUM>, <NUM>. In the region between the pair of endless belts 36a, 36b, there may be positioned a central stationary platform <NUM> of removable panels that permit access to regions under the pair of endless belts 36a, 36b, in particular for servicing and maintenance. It will be appreciated that where the conveyor system <NUM> is provided with two or more endless belts to transport the wheeled structure along the service line <NUM>, the endless belts will move in synchronous motion. As the arrangement for each of the endless belts 36a, 36b is substantially identical, the endless belts 36a, 36b are herein collectively referred to as the endless belt <NUM> unless otherwise specified.

The endless belts 36a, 36b are made of a plurality of plastic belt segments that are hingedly coupled via pins that are typically made of metal or plastic. The plastic of the belt segments has a hardness HBS that enables the belt segments to withstand the load of a vehicle positioned thereon.

Turning now to <FIG>, <FIG> and <FIG>, the conveyor system <NUM> is generally supported within a trench <NUM> having a depth suitable to house the required drive and guide mechanisms, and to permit maneuverability to service personnel. The endless belt <NUM> has an upper transport portion <NUM> and a lower return portion <NUM>, and extends along the conveyor system <NUM> between a drive end <NUM> and an idler end <NUM>. The drive end <NUM> and idler end <NUM> provide axially elongated rollers <NUM> and <NUM>, respectively, which are rotatably supported on a conveyor frame <NUM>, to guide the endless belt <NUM> around the respective drive and idler ends <NUM> and <NUM>.

The drive end <NUM> includes a drive module <NUM> adapted to engage and move the endless belt around the drive and idler ends <NUM> and <NUM>. The drive module <NUM> may be an electric motor as shown, and may include at least one drive member <NUM> to engage the endless belt <NUM> and move it around the respective drive and idler ends <NUM> and <NUM>. As shown, the drive member <NUM> is provided in the form of at least one sprocket <NUM> provided with sprocket teeth <NUM> to engage complementary tracks (not shown) on the inward surface <NUM> of the endless belt <NUM>. The conveyor system <NUM> will additionally include guide members <NUM> supported upon the conveyor frame <NUM> to support the lower return portion <NUM> of the endless belt <NUM> as it moves back towards the idler end <NUM> on the underside of the conveyor system <NUM>. As shown, the guide members <NUM> are provided in the form of rollers.

In motion, the upper transport portion <NUM> of the endless belt <NUM> moves in tension from the idler end <NUM> towards the drive end <NUM> by drive member <NUM>, while the lower return portion <NUM> moves in a slackened state from the drive end <NUM> towards the idler end <NUM>.

Turning now to <FIG> and <FIG>, shown is an enlarged view of the conveyor system <NUM> with the endless belt <NUM> and associated support structure removed to highlight features of the conveyor frame <NUM>. The conveyor frame <NUM> includes a plurality of cross-members <NUM> positioned transversely relative to the longitudinal direction of the service line <NUM>. The cross-members <NUM> are dimensioned to span the width of the trench <NUM>, and are adapted to mount on opposing surfaces <NUM> and <NUM>. Each cross-member <NUM> also provides at least one footing <NUM> at approximately a midpoint thereof, extending to a floor <NUM> of the trench <NUM> to provide additional load-bearing performance to the conveyor frame <NUM>.

Arranged in the longitudinal direction, the conveyor frame <NUM> additionally provides a plurality of support rails that extend the longitudinal length of the service line <NUM>, from the idler end <NUM> to the drive end <NUM>. The support rails are arranged as two inner support rails 78a, 78b and two outer support rails 80a, 80b. The inner support rails 78a, 78b are generally positioned symmetrically about the longitudinal centerline of the service line <NUM>, while the two outer support rails 80a, 80b are situated proximal to the longitudinal walls of the trench <NUM>. The inner support rails 78a, 78b and the outer support rails 80a, 80b may be fixedly attached in place by rivets, threaded fasteners (e.g., bolts), metallurgic bonding (e.g., welded attachment), or any other suitable means to achieve a secure attachment.

Having reference to <FIG>, the inner support rails 78a, 78b cooperatively define a gap spacing for the central stationary platform <NUM> provided between the endless belts 36a, 36b. The inner support rails 78a, 78b each provide a respective seat 82a, 82b configured to receive and support the central stationary platform <NUM>. In the embodiment shown, the central stationary platform <NUM> is provided in the form of fiberglass or thermoplastic grating. In addition, for each endless belt <NUM>, the respective opposing inner and outer rails 78a, 80a define a gap spacing to receive a support deck <NUM>. The support deck <NUM> generally includes a plurality of modular grid panels <NUM> adapted to be positioned end to end relative to one another along the longitudinal length of the service line <NUM>. The modular grid panels are provided with a length that aligns the point of contact between adjacent grid panels on a transverse cross-member <NUM>, providing weight-bearing support thereto. The support deck <NUM> is positioned between the upper transport portion <NUM> and lower return portion <NUM> of the endless belt <NUM>, generally in close proximity to the upper transport portion <NUM>. In this way, the support deck <NUM> provides support to the upper transport portion <NUM> of the endless belt <NUM>, and thereby a load placed thereon from a wheeled structure placed upon the conveyor system <NUM>. To facilitate sliding of the endless belt over the support deck <NUM>, a belt contact surface in the form of a plurality of wear plates <NUM> is provided between the upper transport portion <NUM> and the support deck <NUM>. The belt contact surface is the portion of the support deck <NUM> facing the endless belt <NUM> during normal use. The belt contact surface can have a thickness so that, as it wears through use with the endless belt <NUM>, it continues to facilitate sliding of the endless belt <NUM> thereover until the belt contact surface is worn out.

The wear plates <NUM> form a structure that extends along a top of the support deck <NUM> and contacts the upper transport portion <NUM> of the endless belt <NUM>. The arrangement of the inner and outer support rails 78a, 78b, 80a, 80b may additionally be used to mount the guide member <NUM> supporting the lower return portion <NUM> of the endless belt <NUM>. As shown, the inner and outer support rails 78a, 80a provide respective guide hangers <NUM>, <NUM> that support the guide member <NUM> in a transverse direction relative to the longitudinal direction of the service line <NUM>. As shown, the guide member <NUM> is provided with a plurality of rollers <NUM> that support an outward surface <NUM> of the endless belt <NUM> along the lower return portion <NUM>.

Continuing with <FIG>, also provided between the upper transport portion <NUM> and the lower return portion <NUM> of the endless belt <NUM>, and in particular between the support deck <NUM> and the lower return portion <NUM> is a debris deflector <NUM>. The debris deflector <NUM> provides a barrier to protect the lower return portion <NUM> from debris falling from the support deck <NUM>, in particular where the support deck <NUM> is provided in the form of the modular grid panels. The debris deflector <NUM> is generally mounted on an angle directed downwardly towards the longitudinal centerline of the service line. The debris deflector <NUM> may be mounted on dedicated brackets, or may be mounted on the guide hangers <NUM> and <NUM> used for supporting the guide members <NUM> (as shown). The debris deflector <NUM> is generally configured to provide a contiguous barrier between adjacent cross-members, so as to maximize the protection from falling debris. In some embodiments, the debris deflector <NUM> may be provided in the form of multiple panels arranged and fastened in side-by-side relationship to one another.

It will be recognized that the arrangement of the support deck <NUM>, the debris deflector <NUM> and the longitudinally-spaced cross-members <NUM> define a partial enclosure in the region between the upper transport portion <NUM> and the lower return portion <NUM> of the endless belt <NUM>. To assist in reducing the likelihood of freezing conditions on the conveyor system <NUM>, in particular sections exposed to the outside environment, such as the loading zone <NUM> shown in <FIG>, at least a portion of the conveyor system <NUM> may include a heater in these partial enclosures between adjacent cross-members <NUM>. Referring to <FIG> and <FIG>, the conveyor system <NUM> provides a heater <NUM> positioned between the support deck <NUM> and the debris deflector <NUM>, extending in the longitudinal direction across one or more of the partial enclosures delimited longitudinally between adjacent cross members <NUM>. Accordingly, the partial enclosures containing the heater <NUM> provide a region of higher heat concentration relative to other areas within the trench <NUM>, in particular the area below the debris deflector <NUM>. In this way, the support deck <NUM>, the endless belt <NUM> supported thereon, and the plurality of wear plates <NUM> positioned therebetween receive heat from the region of higher heat concentration, thereby reducing the likelihood of a freeze event in the conveyor system <NUM>. It will be appreciated that freeze events in conveyor systems can result in extensive damage to the endless belt <NUM> and/or drive module <NUM>.

To enable passage of the heater <NUM> between adjacent partial enclosures separated by the cross-members <NUM>, the cross-members <NUM> are adapted with one or more pass-through apertures <NUM>, depending on whether the heater is adapted to pass once through the desired heated portion, or in a serpentine path therethrough. In the embodiment shown in <FIG>, two pass-through apertures are provided for each side of the conveyor system <NUM>.

It will be appreciated that the heater <NUM> may take on a variety of forms. For example, the heater <NUM> may be configured as a convective heater, such as a convective tube heater including both smooth and finned-tube varieties. A convective tube heater will generally be part of a fluid circuit having an electric or gas-fired heater module to deliver a heated fluid therein. The heater <NUM> may also be configured as a radiant heater such as a gas-fired radiant tube heater, or a resistive electrical heating element.

The debris deflector <NUM> may be formed from any suitable material including but not limited to metal (e.g., stainless steel, galvanized steel, aluminum, etc.), thermoplastics (e.g., polypropylene, polyethylene, etc.) and composites. To promote direction of the emitted heat from heater <NUM> towards the support deck <NUM>, the debris deflector <NUM> may be adapted with at least a selected level of thermal reflectivity. The thermal reflectivity may be achieved by constructing the debris deflector <NUM> in the form of a radiant barrier. Alternatively, a radiant barrier may be separately formed and applied to the debris deflector <NUM>, for example in the form of a thin radiant barrier sheet attached thereto. Radiant barriers are typically highly reflective materials (e.g., aluminum or polished stainless steel foil) applied to a substrate. Exemplary substrates may include kraft paper, oriented strand board, plastic films and plywood. For environments that experience high moisture levels, for example a car wash tunnel, the substrate may be of metal or thermoplastic construction. Exemplary thermoplastic substrates may include polypropylene or polyethylene foam core. In general, the material applied to the substrate should exhibit an emittance of less than <NUM>, as measured by ASTM C1371. In addition to polished metallic films, low-emittance coatings such as metal oxide may be used on a suitable substrate. It will be appreciated that the side of the debris deflector <NUM>, or separately formed sheet, facing the support deck <NUM> is the side adapted to receive the highly reflective material. In other words, the highly reflective material, and thus the effective side of the radiant barrier is intended to face the region of higher heat concentration between the debris deflector <NUM> and the support deck <NUM>.

Having regard to <FIG> and <FIG>, shown is a debris deflector <NUM> according an alternative embodiment. As the debris deflector <NUM> is arranged in the conveyor system <NUM> in substantially the same way as debris deflector <NUM>, only the differences associated with this alternative embodiment are discussed. The debris deflector <NUM> includes a debris portion <NUM> that is positioned under the support deck <NUM>, and a water collection portion <NUM> that extends outwardly therefrom, towards a respective side wall of the trench <NUM>. The water collection portion <NUM> is intended to facilitate cleaning of the debris portion <NUM> of the debris deflector <NUM>, without the need for substantial disassembly and associated downtime of the conveyor system. With this arrangement, a sprayer or suitable wash nozzle <NUM> may be positioned as shown to deliver a stream of water directly upon the water collection portion <NUM> of the debris deflector <NUM>, promoting a wash effect to remove accumulated debris from the debris portion <NUM>. Access to the water collection portion <NUM> may be achieved by removing side panels <NUM>, or where the side panels <NUM> are provided in the form of fiberglass or thermoplastic grating, wash water may be delivered directly therethrough. The use of grates for the side panels <NUM> will also permit a greater volume of wash and rinse water from the wash tunnel to be captured by the water collection portion <NUM>, enhancing the cleaning effect of the debris deflector <NUM> during normal wash tunnel usage.

As shown, the water collection portion <NUM> of the debris deflector <NUM> is generally arranged at an angle relative to the debris portion <NUM>, with its terminal lateral edge <NUM> being positioned proximal the underside <NUM> of the side panel <NUM>. The debris deflector <NUM> is provided with a curved transition <NUM> between the water collection portion <NUM> and the debris portion <NUM> to deflect the impingement of rinse water, with reduced turbulence, therein resulting in an effective flushing of debris from the debris portion <NUM> of the debris deflector <NUM>.

The debris deflector <NUM>, <NUM> may be formed of stamped or formed stainless steel, or galvanized steel to provide a rust-inhibiting effect. In an alternative embodiment, the debris deflectors <NUM>, <NUM> may be formed of a thermoplastic material, for example a polyolefin, a low or high-density polyethylene, polyvinyl chloride, or an acrylonitrile butadiene styrene (ABS), and may include suitable fillers or additives to achieve the desired performance characteristics. In general, suitable materials will exhibit resistance to wear, corrosion and pitting, as well as low moisture absorption and low reactivity to chemicals. Suitable materials should also exhibit a general non-stick behavior (i.e., as achieved through improved surface smoothness and a low coefficient of friction) in relation to oil and grease, as well as dirt and salt. In one embodiment, the debris deflector <NUM>, <NUM> may be formed of polypropylene or polyethylene, and may include glass fibers to improve impact performance at low temperature.

When formed of thermoplastic material, the debris deflector <NUM>, <NUM> may be formed via any suitable molding process, including but not limited to vacuum forming, compression molding and thermoforming. When molded, a thermoplastic debris deflector may incorporate one or more structural ribs <NUM> (as seen in <FIG>). The structural ribs <NUM> provide additional rigidity to the debris deflector <NUM>, <NUM>, and establish sluice-like channel-ways <NUM> that direct water flow, enhancing the wash effect.

As stated earlier, and having regard to <FIG>, the upper transport portion <NUM> of the endless belt <NUM> moves in tension from the idler end <NUM> towards the drive end <NUM> by drive member <NUM>, while the lower return portion <NUM> moves in a slackened state from the drive end <NUM> towards the idler end <NUM>. In the slackened state, the lower return portion <NUM> of the endless belt <NUM> may be subject to greater lateral movement, having the potential to create belt tracking and alignment issues. This is particularly evident at the idler end <NUM> where the axially elongated roller <NUM> is not provided with engagement teeth as found on the opposing drive member <NUM> at the drive end <NUM>. Misalignment and poor tracking of the endless belt <NUM> can cause excessive wear on the conveyor mechanism, necessitating increased maintenance and associated downtime. Issues of misalignment of the endless belt <NUM> can increase upon aging of the endless belt <NUM>, generally due to belt stretch. Accordingly, in an alternative embodiment, a least one pair of lateral guide rollers are incorporated into the conveyor system <NUM>.

The wear plates <NUM> are made from a material that is at least partially thermoplastic, and, in particular, at least partially polyethylene, such as an ultra-high-molecular-weight polyethylene ("UHMWPE"), which is also known as high-modulus polyethylene ("HMPE"). UHMWPE is a thermoplastic polyethylene that has extremely long chains. The longer chains serve to transfer load more effectively to the polymer framework by reinforcing intermolecular interactions. Further, UHMWPE has low moisture absorption, a very low coefficient of friction, a high strength, and is highly resistant to abrasion as a result of the longer chains, especially in comparison to carbon steel. Further, UHMWPE is very resistant to corrosion. Some particular exemplary materials that can be used to manufacture the wear plates are virgin UHMWPE such as available from Röchling Engineering Plastics and the Garland Manufacturing Company, reprocessed UHMWPE such as available from Röchling Engineering Plastics, glass filled UHMWPE such as available from Quadrant Plastic Composites Inc. , ceramic filled UHMWPE such as available from Polymer Industries Inc. and Quadrant Plastic Composites Inc. , and cross-linked UHMWPE such as available from Röchling Engineering Plastics and Polymer Industries Inc.

Alternatively, in other embodiments, the wear plates can be made from a material that is at least partially high-density polyethylene ("HDPE"). HDPE is also suitable for use for construction of the wear plates <NUM>. In another embodiment, a proprietary polyethylene, Polystone™ sold by Röchling Engineering Plastics, can be used to manufacture the wear plates.

The material of the wear plates <NUM> can be selected it has a hardness HWP that is lesser than the hardness HBS of the plastic belt segments in some scenarios.

The costs for the manufacturing of wear plates form these materials ranges from <NUM>% to over <NUM>% of the price using stainless steel in some cases, based on the current prices of stainless steel and these thermoplastics. Depending on the material selected and application, suitable thickness ranges are in the <NUM>/<NUM> inch to <NUM>/<NUM> inch range (<NUM>-<NUM>) in some scenarios.

Traditionally, the use of such materials for belt contact surfaces was deemed unsuitable as dirt trapped between the endless belts and the belt contact surfaces caused the belt contact surfaces to wear at an unsatisfactory rate without significant improvements to the wear of the endless belts. Wearing of the endless belts and the belt contact surface occurs in the form of erosion. As the endless belts are worn down, the pins holding belt segments together are exposed and can be deformed and pop out, allowing the belt segments to separate. Erosion of the belt contact surface can accelerate endless belt wear where the endless belt is in contact with the underlying structures.

It has been found that, by using a belt rinsing system that introduces and drains a rinsing fluid between the endless belts and the belt contact surfaces, the dirt trapped between the endless belts and the belt contact surfaces can be reduced and that the wear rate of both the endless belts and the belt contact surfaces can be reduced.

That is, by making the belt contact surface (i.e., the wear plates <NUM>) from a softer material than stainless steel that is traditionally used, and by rinsing away debris from the interface between the endless belts 36a, 36b and the support deck, the lifetime of the endless belts 36a, 36b can be increased as a result of the lower wear from contact with the wear plates <NUM>.

Certain thermoplastics, such as UHMWPE and HDPE have been found to be suitable due to their possession of certain characteristics. These materials provide a sufficiently low coefficient of friction, and are sufficiently resistant to abrasion. The wear plates <NUM> are inexpensive to replace relative to the replacement cost of the endless belts 36a, 36b. The replacement cost of an endless belt 36a, 36b can be high as there is a significant amount of manual labor in disassembling the belt segments to be replaced. Wear plates made from a material that is substantially UHMW have been found to have a service lifetime that ranges from <NUM>% to <NUM>% of the durability of wear plates made from stainless steel. Of more interest is that, due to the relative softness, higher resistance to abrasion, and lower coefficient of friction of the material compared to stainless steel traditionally employed in these applications, the wear rate of the endless belts is reduced, thus extending their service lifetime significantly, anywhere from <NUM>% to <NUM>% in some cases.

Another characteristic of thermoplastics is that they generally have a hardness HWP that is lesser than the hardness HBS of the belt segments of the endless belts 36a, 36b. As a result, the wear plates <NUM> are designed to improve the lifetime of the endless belt <NUM> by sacrificing the lifetime of the wear plates <NUM>.

Polyethylenes and other thermoplastics are subject to thermal expansion and contraction. In the car wash environment, the range of temperatures that the wear plates <NUM> are subject to is significant. The wear plates <NUM> have a longitudinal length of approximately <NUM> (<NUM> inches) and have been found to expand and contract +/- <NUM> ( +/- <NUM> inches) over a typical operational ambient temperature range. In order to compensate for these expansions and contractions, expansion gaps between the leading and trailing edges <NUM> and <NUM> of the wear plates <NUM> of <NUM> (<NUM> inches) or greater are provided.

Each wear plate <NUM> is provided with a plurality of debris slots <NUM> that permit the evacuation of debris therethrough, so as to reduce the accumulation of debris between the endless belt and the wear plates <NUM>. Each debris slot <NUM> includes a first slot end <NUM> and a second slot end <NUM>, and is provided with a width of <NUM>, although widths of between <NUM> to <NUM> may be implemented. Each debris slot <NUM> may be linear (i.e., straight) and may be arranged at an angle θ relative a longitudinal centerline L of the wear plate <NUM>. As shown, the debris slot <NUM> is outwardly angled from the longitudinal centerline L in the direction of the first slot end <NUM> towards the second slot end <NUM>. The angle θ of each debris slot <NUM> is <NUM>° relative to the longitudinal centerline L of the wear plate <NUM>, although angles between <NUM>° to <NUM>° may be implemented. In general, angle selection is based on observed belt wear. It has been determined that angles within this range, and in particular at <NUM>° relative to the longitudinal centerline L of the wear plate <NUM> result in the least amount of endless belt wear during use, therein increasing the usable lifespan of the endless belt and wear plates.

The first slot end <NUM> and the second slot end <NUM> of each debris slot <NUM> can be provided with an inwardly sloped bevel <NUM>, as shown in <FIG>. It has been determined that maximum wear of the endless belt occurs where the endless belt passes over a sharp edge perpendicular to the direction of belt travel. Accordingly, with the first and second slot ends <NUM> and <NUM> having the inwardly sloped bevel <NUM>, in particular at the second slot end <NUM>, the extent of belt wear is reduced, particularly when the wear plates are constructed of stainless steel. Between the first and second slot ends <NUM> and <NUM> of the debris slot <NUM>, the opposing edges 178a and 178b remain unbeveled, that is they remain as sharp edges, as shown in <FIG>. As the endless belt is passing over these sections of the debris slot <NUM> at an angle (i.e., <NUM>° relative to the longitudinal centerline L of the wear plate <NUM>), the extent of belt wear is minimal. Moreover, by maintaining these edges sharp as shown, they provide a stripping action to remove debris from the underside of the endless belt, without excessive wear thereto.

It will be appreciated that while both the first and second slot ends <NUM> and <NUM> are shown as being beveled, in some embodiments, only one of the first and second slot ends <NUM> and <NUM> is beveled. In an alternative embodiment, only the second slot end <NUM> is beveled.

By using certain thermoplastics that are softer than stainless steel, have a low coefficient of friction, and/or a high resistance to abrasion in constructing the wear plates, it has been found that the beveling of the debris slots <NUM> as shown in <FIG> can be omitted without materially increasing wear on the endless belt <NUM>. The beveling of the debris slots <NUM> adds to the manufacturing costs of the wear plates <NUM> and, thus, the ability to omit this feature without materially impacting the lifetime of the endless belt <NUM> is another benefit to the use of thermoplastics in the construction of the wear plates <NUM>.

In the embodiment shown in <FIG>, each wear plate <NUM> provides <NUM> debris slots <NUM>, generally presented in two rows of <NUM> arranged across the wear plate <NUM>. Within each row, the <NUM> debris slots are arranged in two paired sets of debris slots, with the two paired sets of debris slots being longitudinally offset relative to one another. The arrangement of the debris slots <NUM> is such that the leading and trailing ends <NUM> and <NUM> of successive debris slots <NUM> align, so as to reduce the number of locations having increased potential for belt wear. As shown, alignment between successive debris slots occurs along longitudinal centerline L, as well as alignment line ALA and alignment line ALs.

It will be appreciated that while each wear plate <NUM> is shown as having <NUM> debris slots <NUM>, in other embodiments, the number of debris slots <NUM> may be fewer or greater, depending on the extend of debris removal required. While the leading and trailing ends <NUM> and <NUM> of all debris slots <NUM> may be machined with the aforementioned inwardly sloped bevel, in some embodiments, only the debris slots <NUM> arranged proximal the longitudinal centerline L of the wear plate <NUM> may be beveled. In other preferred embodiments, the debris slots <NUM> are not beveled.

Reference is made to <FIG>, which shows the conveyor system <NUM> with an optional rinsing system <NUM>. The rinsing system <NUM> includes a rinsing system conduit arrangement <NUM> (a portion of which is shown in <FIG> and <FIG>), which is connectable to a source of rinsing system liquid (e.g., a city water supply). The rinsing system <NUM> further includes at least one belt rinsing arrangement <NUM>. In the present example, the rinsing system <NUM> includes a plurality of belt rinsing arrangements <NUM> spaced longitudinally apart for rinsing the upper transport portion <NUM> of the endless belt <NUM>.

Each belt rinsing arrangement <NUM> includes a rinsing system dirt pass-through aperture <NUM> in the support deck <NUM>, over which the upper transport portion <NUM> of the endless belt <NUM> travels during operation. As can be seen, in the embodiment shown in <FIG>, the rinsing system dirt pass-through aperture <NUM> is provided in a rinsing system wear plate <NUM>. The rinsing system dirt pass-through aperture <NUM> may be similar to the debris slots <NUM> in the wear plates <NUM>, but may be wider in the direction of travel (shown at Dt) of the endless belt <NUM> for reasons provided below.

Each belt rinsing arrangement <NUM> further includes at least one rinsing system outlet <NUM> from the rinsing system conduit arrangement <NUM> positioned proximate to the rinsing system dirt pass-through aperture 306a and positioned to eject rinsing system liquid (shown at <NUM> in <FIG> and <FIG>) onto the endless belt <NUM> upstream from a downstream edge <NUM> of the rinsing system dirt pass-through aperture 306a in order to capture at least some of the ejected liquid <NUM> through the rinsing system dirt pass-through aperture 306a. The terms 'upstream' and 'downstream' are both in relation to the direction of travel Dt of the upper transport portion <NUM> of the endless belt <NUM>. The upstream edge of the rinsing system dirt pass-through aperture 306a is shown at <NUM>. Additional rinsing system dirt pass-through apertures 306b enables the flushing of ejected liquid <NUM> downstream of the rinsing system dirt pass-through apertures 306a.

Put another way, the rinsing system <NUM> can rinse off dirt from the endless belt <NUM> so as to prevent that dirt from causing wear on the belt <NUM> as the belt <NUM> moves along during operation. The dirt may be present directly at the sliding interface between the belt <NUM> and the wear plates <NUM> and <NUM>. Additionally, the dirt may be present at the pins (shown at <NUM>) that pivotally connect belt segments (shown at <NUM>) that make up the belt <NUM>.

Pockets (shown at <NUM>) are present in the endless belt <NUM> and some portions of the pins <NUM> are exposed in the pockets <NUM>. It is therefore beneficial for the rinsing system <NUM> to be able to eject rinsing system liquid into the pockets <NUM> to rinse dirt from the pins <NUM>. This inhibits dirt from migrating into the interface between the pins <NUM> and the associated surfaces of the belt segments <NUM>, which reduces the wear that can occur on the belt segments <NUM> at that interface. Such wear contributes to ovalizing of the apertures in the belt segments <NUM> in which the pins <NUM> reside, causing the belt <NUM> to lengthen and contributing to accelerated wear and failure of the belt <NUM>.

Thus it may be said that the endless belt includes a plurality of belt segments <NUM> that are pivotally connected to one another via at least one pin <NUM> that extends laterally. The endless belt <NUM> includes at least one pocket <NUM> that exposes the at least one pin <NUM>. The at least one rinsing system outlet <NUM> is positioned to eject rinsing system liquid into the at least one pocket <NUM> onto the at least one pin <NUM> to remove dirt from the at least one pin <NUM>.

The rinsing system outlet <NUM> may be any suitable type of outlet that is capable of ejecting rinsing system liquid the distance needed to remove dirt from the endless belt <NUM>. In some examples, the pressure of the rinsing system liquid at the rinsing system outlet <NUM> may be about <NUM> kPa (<NUM> psi) or higher. In some examples, it may be <NUM> kPa (<NUM> psi) or higher. The rinsing system outlet <NUM> may, for example, be a nozzle.

Reference is made to <FIG>. As can be seen, the rinsing system outlets <NUM> are positioned below the wear plates <NUM> and are positioned to eject the rinsing system liquid up through the rinsing system dirt pass-through aperture <NUM> into the belt <NUM>. The rinsing system dirt pass-through aperture <NUM> has an elongate cross-sectional shape and is sized to permit the ejecta <NUM> (i.e., the rinsing system liquid ejected therefrom) to leave upwardly from the rinsing system dirt pass-through aperture <NUM>, to hit the endless belt <NUM> and to fall through the rinsing system dirt pass-through aperture <NUM> after hitting the endless belt, bringing dirt with it, as shown in <FIG>. For example, in the embodiment shown, the outlet <NUM> is well below the wear plate <NUM> and so the ejecta <NUM> pass upwardly through the rinsing system dirt pass-through aperture <NUM>, hit the belt <NUM> and then fall back down through the aperture <NUM>.

The apertures <NUM> are shown as being angled, similarly to the apertures (slots) <NUM> in the wear plates <NUM>, for the purpose of ensuring that segments of the belt <NUM> are always supported and do not impact against an aperture edge. This is the same reason described for the angle of the slots <NUM>. Similar angular ranges may be used for the orientation (i.e., the angle) of the apertures <NUM>.

As can be seen, each rinsing system outlet <NUM> is in the form of a fan jet nozzle configured for ejecting rinsing system liquid <NUM> in the form of ejecta <NUM> having an elongate cross-sectional shape (e.g., a flat spray pattern).

Referring to <FIG>, dashed lines shown at 330a and 330b represent the side edges of the endless belt <NUM>. The belt <NUM> has a width W. As can be seen, the at least one belt rinsing arrangement <NUM> includes enough of the rinsing system outlets <NUM> to eject rinsing system liquid <NUM> (i.e., ejecta <NUM>) on the entire width of the belt <NUM>. There is some offset between the apparent position of the ejecta <NUM> and the position of the side edges 330a and 330b of the belt <NUM> in the view shown in <FIG> however, it will be understood that this is merely a result of the difference in elevation of the outlets <NUM> and the belt <NUM>.

In <FIG>, a debris deflector <NUM> is provided and may be similar to any of the debris deflectors shown and described herein. The debris deflector <NUM> is positioned underneath the rinsing system dirt pass-through aperture <NUM> to collect dirt falling through the rinsing system dirt pass-through aperture <NUM>, and sloped downwardly away from the rinsing system dirt pass-through aperture <NUM> in order to transport collected dirt towards a dirt collection area shown at <NUM>.

Reference is made to <FIG> and <FIG>, which show another rinsing system <NUM>, which includes a rinsing system conduit arrangement <NUM> which is connectable to a source of rinsing system liquid (e.g., a city water supply or a reclaim water system). The rinsing system <NUM> further includes at least one sprocket rinsing arrangement <NUM> configured to rinse and remove dirt from a sprocket arrangement <NUM> that is used to drive the belt <NUM>. The sprocket arrangement <NUM> in the present example includes a plurality of sprockets <NUM> that are mounted on a drive shaft <NUM>. Alternatively, the sprocket arrangement <NUM> could include a single sprocket <NUM>.

The drive shaft <NUM> in the present example is square and passes through square apertures in the sprockets <NUM>, however it will be understood that other shapes for the drive shaft <NUM> and apertures are possible. The sprocket arrangement <NUM> has sprocket teeth <NUM> that engage the belt <NUM> to drive the belt <NUM>. The direction of rotation of the sprocket arrangement <NUM> is shown at Ds in <FIG>.

Each belt rinsing arrangement <NUM> further includes at least one rinsing system outlet <NUM> from the rinsing system conduit arrangement <NUM>. The at least one rinsing system outlet <NUM> is positioned proximate to the sprocket arrangement <NUM> and is positioned to eject rinsing system liquid <NUM> onto the sprocket arrangement <NUM>.

As rinsing system liquid <NUM> is ejected onto the sprocket arrangement <NUM>, it rinses some dirt off a portion of the surface of the sprocket arrangement <NUM> prior to engagement between that portion of the surface of the sprocket arrangement <NUM> and the belt <NUM>. As a result, there is less dirt that would cause wear of the belt <NUM> during engagement with the sprocket arrangement <NUM>. Such wear on the belt <NUM> can reduce the efficacy of the engagement with the teeth <NUM> on the sprocket arrangement <NUM>. Additionally, the presence of the dirt itself can inhibit good engagement between the teeth <NUM> and the belt <NUM> which can result in increases stresses on certain areas of the belt <NUM> during such engagement.

A debris collection guide <NUM> is provided underneath the at least one rinsing system outlet <NUM> to collect at least some of the liquid that has hit the sprocket arrangement <NUM> and reflected or dripped off the sprocket arrangement <NUM> thereafter along with any dislodged dirt or any dirt entrained in the reflected liquid or the liquid that has dripped off the sprocket arrangement <NUM>. The debris collection guide <NUM> guides collected debris to a debris collection area (not shown).

Some rinsing system liquid <NUM> may wind up on the lower return portion <NUM> of the belt <NUM> instead of in the debris collection guide <NUM>. This is not considered problematic, since the inner surface of the lower return portion (shown in <FIG> at <NUM>) does not engage any surfaces with significant force until reaching the idler drum at the other end of the conveyor system <NUM>. Some of the dirt and liquid collected on the inner surface <NUM> of the lower return portion <NUM> of the belt <NUM> will have fallen off the belt <NUM> by the time it reaches the other end. As noted above, the rinsing system <NUM> can be provided at the upstream end of the upper transport portion <NUM> of the conveyor system <NUM>, so as to rinse off dirt thereon prior to a lot of sliding engagement with the wear plates <NUM>.

<FIG> is a perspective view of the rinsing system <NUM>, but with the sprocket arrangement <NUM> removed. As shown in <FIG>, the rinsing system outlets <NUM> may be in the form of fan (flat spray) jet nozzles, and may be configured to eject rinsing system liquid <NUM> in flow patterns that overlap with one another and which are configured to cover the width of the sprocket arrangement <NUM>.

As can be seen in <FIG> and <FIG>, optionally, the rinsing system <NUM> further includes at least one belt rinsing arrangement including at least one rinsing system outlet <NUM> positioned to spray rinsing system liquid <NUM> on the outer face (shown at <NUM>) of the belt <NUM>, to further clean the belt <NUM> while the belt <NUM> is engaged with the sprocket arrangement <NUM>.

Reference is made to <FIG> and <FIG>, which show a flooder system <NUM> for the conveyor system <NUM>. The flooder system <NUM> is used to introduce liquid between the endless belt <NUM> and the wear plate (e.g., wear plate <NUM> or wear plate <NUM>). The flooder system <NUM> includes a flooder system conduit arrangement <NUM> connectable to a source of flooder system liquid (such as city water, or a source of city water mixed with soap, wax or some other lubricant), and at least one belt flooding member <NUM>. Each belt flooding member <NUM> includes at least one flooding system outlet <NUM> (and optionally a plurality of outlets <NUM> which are spaced apart laterally) from the flooding system conduit arrangement <NUM>. The outlet or outlets <NUM> are positioned underneath the endless belt <NUM> and are positioned to introduce flooding system liquid <NUM> between the endless belt <NUM> and the wear plate. The liquid <NUM> introduced helps to reduce friction between the belt <NUM> and the wear plate <NUM> or <NUM> in part by entraining dirt that may be present therebetween.

The liquid pressure at the outlets <NUM> may be relatively low, lower than the pressure at the outlets <NUM>. For example, the pressure may be about <NUM> kPa (<NUM> psi), but is preferably higher, such as in the range of <NUM> - <NUM> kPa (<NUM> - <NUM> psi) or even higher.

The support deck (e.g., the wear plates <NUM> and <NUM>) includes a plurality of dirt pass-through apertures as described above. These apertures will permit the dirt and liquid from the flooding system to fall through, thereby removing dirt from the interface between the belt <NUM> and the wear plates <NUM> and <NUM>. The flooding system <NUM> may include a plurality of belt flooding members <NUM> positioned at selected distances longitudinally from one another, such as, for example, about every <NUM> to <NUM> meters (<NUM> to <NUM> feet) from one another. Optionally, each belt flooding member <NUM> is positioned between gratings <NUM> that support the wear plate <NUM> or <NUM> and thus may act as a spacer between these gratings <NUM>. The gratings <NUM> need not be gratings and may also be identified more broadly as wear plate support members <NUM>. The wear plate <NUM> or <NUM> has flooding system apertures <NUM>. Each flooding member <NUM> may include a bar <NUM> that acts as a manifold and that has a plurality of outlets <NUM> thereon. The flooding member <NUM> may further include seal members <NUM> (e.g., rubber bushings) that are positioned between the outlets <NUM> and the underside (shown at <NUM>) of the wear plate <NUM> or <NUM> to form a seal therebetween.

<FIG> show wear plates <NUM> in accordance with another embodiment. The wear plates <NUM> are similar in size and construction to wear plates <NUM> shown in <FIG>, <FIG>, 11a, and 11b. In particular, each of the wear plates <NUM> includes a leading edge <NUM> and a trailing edge <NUM>, wherein the leading and trailing edges <NUM> and <NUM> are provided with complementary profiles to facilitate fit and alignment between adjacently positioned wear plates <NUM>. In the embodiment shown, the complementary profile is provided generally in the form of a chevron aligned to the direction of travel of the vehicle through the wash tunnel. At least one of the leading and trailing edges <NUM> and <NUM> of the wear plates <NUM> may be chamfered to reduce the likelihood of wear upon the endless belt.

Like the wear plates <NUM>, the wear plates <NUM> expand and contract with temperature changes. To allow for this expansion and contraction, the wear plates <NUM> are secured via fasteners inserted through fastener holes <NUM> that fit within slotted holes of the modular grid panels of the support deck. This arrangement allows a degree of freedom of movement (or, more to the point, expansion) of the wear plates <NUM>. It can also be desirable to maintain the leading and trailing edges <NUM> and <NUM> in lateral alignment to avoid changes in the lateral profile of the belt contact surface (i.e., the wear plates <NUM>) in the longitudinal direction that can serve to more quickly wear and/or damage the endless belt.

To this end, the wear plates <NUM> have mating features inhibiting lateral shifting of the wear plates <NUM> relative to one another in the form of fingers <NUM> that extend longitudinally (i.e., generally along the direction of travel of the endless belt) forward from lateral ends of the leading edges <NUM>, and corresponding finger recesses <NUM> that extend longitudinally from lateral ends of the trailing edges <NUM>. The fingers <NUM> mate with the finger recesses of adjacent wear plates <NUM> to maintain the wear plates <NUM> in lateral alignment while the wear plates <NUM> expand to reduce an expansion gap <NUM> between the wear plates <NUM>, and contract.

In other embodiments, the fingers can extend longitudinally from the trailing edge and mate with corresponding finger recesses of the leading edge of an adjacent wear plate. Alternatively, a finger and a recess can be located on opposite lateral ends of each leading and trailing edge and mate with the corresponding features of adjacent wear plates. Other types of mating features that inhibit lateral shifting of the wear plates will occur to those skilled in the art.

The wear plates <NUM> also have debris slots <NUM> that permit the evacuation of debris therethrough, so as to reduce the accumulation of debris between the endless belt and the wear plates <NUM>.

<FIG> and <FIG> show two variants of the design of the wear plates. A wear plate <NUM> shown in <FIG> has fingers <NUM> that extend longitudinally (i.e., generally along the direction of travel of the endless belt) forward from lateral ends of the leading edge <NUM>, and corresponding finger recesses <NUM> that extend longitudinally from lateral ends of the trailing edge <NUM>. The fingers <NUM> mate with the finger recesses of adjacent wear plates <NUM> to maintain the wear plates <NUM> in lateral alignment while the wear plates <NUM> expand to reduce an expansion gap between the wear plates <NUM>, and contract. A set of four locating slots <NUM> are positioned two along each lateral side of the wear plate <NUM>. The wear plate <NUM> has a pattern of debris slots <NUM> that differs from those shown in the previous figures. In particular, the debris slots <NUM> are wider and shorter, enabling ample drainage without significantly affecting the structural integrity of the wear plate <NUM>. That is, there are no portions of the wear plate <NUM> that are connected to the remainder of the wear plate <NUM> only by narrow sections.

A wear plate <NUM> shown in <FIG> has similar features to the wear plate <NUM> of <FIG>, but has different pattern of varying dimensioned debris slots. A first set of longitudinal debris slots <NUM> are generally rectangular with rounded corners, similar to the debris slots described and illustrated above, and are located centrally between the lateral sides <NUM> of the wear plate <NUM>. A second set of peripheral debris slots <NUM> extend adjacent to the lateral sides <NUM> of the wear plate <NUM>. Each of the peripheral debris slots <NUM> has a longitudinal portion <NUM> extending along a similar direction as the longitudinal debris slots <NUM>, and a lateral portion <NUM> that deviates from the longitudinal portion <NUM> and extends along the travel direction dt of the belt. It has been found that, in some cases, debris travels down the lateral sides of the endless belts and gets underneath between the endless belt and the wear plates. The peripheral debris slots <NUM>, and their lateral portions <NUM> in particular, assist in quickly flushing away this debris to reduce its chances of lingering between the endless belt and the wear plate <NUM>.

<FIG> shows locating features of a wear plate <NUM> and an edge guide <NUM> that assist with maintaining the correct alignment of the wear plates <NUM> while enabling them to expand and contract as a result of fluctuations in the operating temperature. The wear plates <NUM> have locating slots <NUM> along their lateral edges. The edge guide <NUM> is made of <NUM> gauge stainless steel that has a curved profile, enabling it to be deflected as the wear plates <NUM> are being positioned. Locating tabs <NUM> of the edge guide <NUM> mate with the locating slots <NUM> of the wear plates <NUM>. The size of the locating tabs <NUM> and the locating slots <NUM> are selected to enable the wear plates <NUM> to expand and contract.

<FIG> show a wear plate <NUM> and a set of the wear plates <NUM> in use in a conveyor system according to the invention. The conveyor system is similar to those shown in <FIG>.

A set of the wear plates <NUM> are shown deployed as part of a support deck <NUM> for an endless belt <NUM>, a portion of which is shown. The support deck <NUM> is similar to the support deck <NUM> shown in <FIG>, <FIG> except that it is adapted for the wear plates <NUM>. The support deck <NUM> generally includes a plurality of modular grid panels <NUM> adapted to be positioned end to end relative to one another along the longitudinal length of the service line. The modular grid panels <NUM> are made of fibre-reinforced plastic (hereinafter "FRP") or another material that is suitably hard. FRP is more economical than stainless steel for grid panels, but does not possess the same resistance to bending that stainless steel has. Accordingly, the modular grid panels <NUM> are positioned atop of three inner support rails <NUM>, with the central inner support rail <NUM> supporting the centre of the modular grid panels <NUM> that generally bears the most load when a vehicle is being transported by the conveyor system. A pair of carryway channels <NUM> extend along either side of the support deck <NUM> and are bolted to transverse I-beams, such as those shown in <FIG>.

The support deck <NUM> is positioned between an upper transport portion of the endless belt <NUM>, shown in <FIG>, and a lower return portion of the endless belt <NUM>. In this way, the support deck <NUM> provides support to the upper transport portion of the endless belt <NUM>, and thereby a load placed thereon from a wheeled structure placed upon the conveyor system.

To facilitate sliding of the upper transport portion of the endless belt <NUM> over the support deck <NUM>, a belt contact surface <NUM> is provided on an upper surface of the support deck <NUM>. The belt contact surface <NUM> is the portion of the support deck <NUM> facing the upper transport portion of the endless belt <NUM> during normal use. The belt contact surface <NUM> includes a set of the wear plates <NUM> as well as a set of ceramic inserts <NUM> positioned within openings <NUM> of the wear plates <NUM>.

The wear plates <NUM> are similar in size and construction to the wear plates of <FIG>, and are made from a material that is at least partially from a polymer. The polymer can be a thermoplastic, such as a polyethylene, in some implementations. Preferably, the material is an ultra-high-molecular-weight polyethylene or a high-density polyethylene.

Each of the wear plates <NUM> includes a leading edge <NUM>, a trailing edge <NUM>, and two parallel lateral edges <NUM> that are generally straight. A pair of securement apertures <NUM> are positioned adjacent to each of the lateral edges <NUM>. The leading edge <NUM> and the trailing edge <NUM> are designed so that the trailing edge <NUM> of the wear plate <NUM> mates with the leading edge <NUM> of an adjacent wear plate <NUM>.

A set of clamping edge guides <NUM> are secured to the carryway channels <NUM> via a set of bolts or any other suitable means after positioning of the wear plates <NUM> on the modular grid panels <NUM>. Each of the clamping edge guides <NUM> has a clamping portion <NUM> that clamps one or more wear plates <NUM> (depending on the sizing, but two halves in the illustrated embodiment) towards the modular grid panels <NUM> close to the lateral edges <NUM>. Retaining tabs <NUM> of the clamping portion <NUM> fit within the securement apertures <NUM>. The clamping edge guides <NUM> restrict lateral movement of the endless belt <NUM> as it travels over the belt contact surface <NUM>.

The wear plates <NUM> expand and contract with temperature changes. To allow for this expansion and contraction, the wear plates <NUM> are secured via the clamping edge guides <NUM> so that their general longitudinal position along the modular grid panels <NUM> is fixed via the retaining tabs <NUM> inserted into the securement apertures <NUM>. The securement apertures <NUM> of the wear panels <NUM> extend further longitudinally than the retaining tabs <NUM> of the clamping edge guides <NUM>, thus enabling expansion of the wear plates <NUM> longitudinally. The wear plates <NUM> have mating features inhibiting lateral shifting of the wear plates <NUM> relative to one another in the form of fingers <NUM> that extend longitudinally (i.e., generally along the direction of travel of the endless belt) forward from lateral ends of the leading edges <NUM>, and corresponding finger recesses <NUM> that extend longitudinally from lateral ends of the trailing edges <NUM>. The fingers <NUM> mate with the finger recesses <NUM> of adjacent wear plates <NUM> to maintain the wear plates <NUM> in lateral alignment while the wear plates <NUM> expand to reduce an expansion gap <NUM> between the wear plates <NUM>, and contract.

Each of the ceramic inserts <NUM> is rectangular, having four lateral sides <NUM> that meet at right angles. The ceramic inserts <NUM> may be commercially available ceramic tiles or may be custom-made. In particular, the ceramic inserts <NUM> may be ceramic tiles produced for lining chutes in mining operations that are made of approximately <NUM> percent aluminum oxide, and other agents, such as a bonding agent or agents.

According to the invention and as illustrated in <FIG>, the ceramic insert <NUM> is bonded to a compressible layer in the form of a compressible backing <NUM> that enables slight downward depression of the ceramic insert <NUM> when positioned in one of the openings <NUM>. In particular, the compressible backing <NUM> is made at least partially of a neoprene rubber of suitable durometer and thickness, but, in other embodiments, any other suitably resilient and compressible material can be employed. It has been found that, by using the compressible backing <NUM> with the ceramic inserts <NUM>, the incidence of fracturing of the ceramic inserts <NUM> as a result of slight variations in the thickness of the wear plates <NUM> or the flatness of a support surface upon which the wear plates <NUM> and the ceramic inserts <NUM> are positioned is significantly less frequent. In this manner, the compressible backing <NUM> is positioned under the ceramic inserts <NUM> to facilitate depression of the ceramic inserts <NUM> relative to the wear plate <NUM>.

In other embodiments not part of the invention, however, the compressible layer can be omitted or can be deployed under both the wear plates <NUM> and the ceramic inserts <NUM> with corresponding cut-outs for rinsing system dirt pass-through apertures and flooder apertures.

Further, it can be advantageous to ensure that the top of the modular grid panels <NUM> are generally level to reduce uneven load on the ceramic inserts <NUM> as the wheels of a vehicle positioned on the endless belt <NUM> travel thereover. It has been found that a gritty side of the modular grid panels <NUM> is more level than the non-gritty side as the gritty substance applied to the gritty side forms a more uniformly level surface.

The wear plates <NUM> are manufactured via molding to have a thickness twp. A thickness tci of the ceramic inserts <NUM> and the compressible backing <NUM>, if present, corresponds generally to the thickness twp of the wear plates <NUM>. The thickness twp of the wear plates <NUM> may be selected to be slightly greater than the thickness tci of the ceramic inserts <NUM> so that any acceptable variances in the thickness tci of the ceramic inserts <NUM> won't exceed the thickness twp of the wear plates <NUM> to thereby avoid fracturing of the ceramic inserts <NUM>. Where compressible backing is not deployed with the ceramic inserts <NUM>, it may be more desirable to select a thickness twp for the wear plates <NUM> that is marginally greater than in scenarios where the compressible backing <NUM> is deployed, as the compressible backing <NUM> provides tolerance to slight projection of a ceramic insert <NUM> over the wear plate <NUM>.

The ceramic inserts <NUM> are oriented in a pattern along a central band Bc of the wear plate <NUM>. In particular, the ceramic inserts <NUM> are oriented so that the lateral sides <NUM> of the ceramic inserts <NUM> are at angles between <NUM> degrees and <NUM> degrees, and preferably at <NUM> degrees, to a longitudinal direction of travel dt of an endless belt traveling thereover. The orientation of the lateral sides <NUM> of the ceramic inserts <NUM> at <NUM> degrees has been found to reduce wear on an endless belt in comparison to other orientations, particularly where the lateral sides <NUM> of the ceramic inserts <NUM> are oriented perpendicular to the direction of travel dt of the endless belt.

Segments of the leading edge <NUM> and the trailing edge <NUM> of the wear plate <NUM> that are adjacent to ceramic inserts <NUM> are generally parallel to a closest one of the lateral sides <NUM> of the adjacent ceramic insert <NUM>. Traditional wear plates typically have leading and trailing edges that are transverse to the longitudinal direction of travel dt of the endless belt <NUM>. If such transverse edges were employed with the wear plate <NUM> with the obliquely oriented ceramic inserts <NUM>, the gap between the ceramic inserts <NUM> would be significant. By jagging the leading and trailing edges <NUM>, <NUM> of the wear plates <NUM>, the gap between the pattern of obliquely oriented ceramic inserts <NUM> on adjacent wear plates <NUM> can be significantly reduced, and, thus, wear on the central band Bc around the leading and trailing edges <NUM> and <NUM> can be reduced.

The position of a wheel atop of the endless belt <NUM> is shown generally at W. It has been found with conventional wear plates that, as wheels of a vehicle are generally more likely to be centrally positioned on an endless belt traveling over the wear plates, the greatest wear occurs along a central region of the belt contact surface <NUM> extending longitudinally. By employing the ceramic inserts <NUM>, which have a relatively high resistance to abrasion, along the central band Bc, along which wheels such as wheel W are most likely to be positioned, the wear plates <NUM> wear more evenly, thus extending the lifetime of the wear plates <NUM> and the overall maintenance cost of the conveyor system.

The openings <NUM> within the wear plate <NUM> in which the ceramic inserts <NUM> are received are formed via any suitable known means such as milling, water jet cutting, etc. Each opening <NUM> is dimensioned so that is at least partially unobstructed when one of the ceramic inserts <NUM> is positioned therein. In particular, when the ceramic inserts <NUM> are inserted into the openings <NUM>, one or more gaps <NUM> are present between the wear plate <NUM> and each of the ceramic inserts <NUM>. The gaps <NUM> extend through the wear plate <NUM>.

The openings <NUM> are sufficiently spaced from one another so that the strength of the wear plate <NUM> is not significantly compromised. A minimum spacing between openings <NUM> factors in the presence of the gaps <NUM>. The pattern of the ceramic inserts <NUM> along the central band Bc is selected based on a number of factors. Increasing the surface area of the central band Bc of the wear plate <NUM> covered by ceramic inserts <NUM> increases the resistance to abrasion of the belt contact surface <NUM> provided by the wear plates <NUM> and the ceramic inserts <NUM>. Increases in the size of the ceramic inserts <NUM> can lead to a greater chance of fracturing of the ceramic inserts <NUM>. Increasing the spacing between ceramic inserts <NUM> improves the strength of the wear plates <NUM>, but decreases the resistance to abrasion of the belt contact surface <NUM>. It has been found that, by using rectangular ceramic inserts <NUM> and arranging the openings <NUM> for the ceramic inserts <NUM> as closely as possible without significantly deteriorating the strength of the wear plate <NUM> so that the lateral sides <NUM> of the ceramic inserts <NUM> are positioned at <NUM> degree angles relative to the direction of travel dt, various advantages can be realized. Currently produced ceramic tiles can be used as ceramic inserts <NUM>, thereby reducing the cost of production. Further, the strength of the wear plate <NUM> is maintained at a desirable level. Still further, degradation of the endless belt traveling thereacross is improved relative to conventional belt contact surfaces.

The central band Bc is spaced from the lateral edges <NUM> of the wear plate <NUM> by peripheral bands Bp. A number of rinsing system dirt pass-through apertures <NUM> are situated along the peripheral bands Bp to facilitate rinsing of debris from between an endless belt positioned thereon and the belt contact surface <NUM> provided by the wear plate <NUM> and the ceramic inserts <NUM>. Each of the rinsing system dirt pass-through apertures <NUM> is aligned with at least one rinsing system outlet from a rinsing system conduit arrangement positioned proximate to the rinsing system dirt pass-through aperture <NUM> and positioned to eject rinsing system liquid onto an endless belt upstream from a downstream edge of the rinsing system dirt pass-through aperture <NUM> in order to capture at least some of the ejected liquid through the rinsing system dirt pass-through aperture <NUM>.

A belt rinsing system is provided in the conveyor system, and includes a rinsing system conduit arrangement <NUM> that is connected to a source of rinsing system liquid and at least one belt rinsing arrangement. Each belt rinsing arrangement includes at least one rinsing system outlet <NUM> that is positioned proximate to one of the rinsing system dirt pass-through aperture <NUM> and the gaps <NUM> (which acts as a rinsing system dirt pass-through aperture) to eject rinsing system liquid onto the endless belt <NUM> upstream from a downstream edge of the rinsing system dirt pass-through aperture in order to capture at least some of the ejected liquid through the rinsing system dirt pass-through aperture. The rinsing system liquid rinses away debris from between the belt contact surface <NUM> and the endless belt <NUM> positioned thereon. Still further, a flooder system <NUM> similar to that illustrated in <FIG> is employed to introduce liquid between the endless belt <NUM> and the belt contact surface <NUM> via the gaps <NUM> and the rinsing system dirt pass-through apertures <NUM>. The rinsing system and the flooder system <NUM> induce the clearing of debris from between the belt contact surface <NUM> and the endless belt <NUM> and introduce water therebetween to facilitate travel of the endless belt <NUM> over the belt contact surface <NUM>.

In a preferred embodiment, the width of the central band Bc is between <NUM>% and <NUM>% of the entire width of the wear plate <NUM>, and in particular, between <NUM>% and <NUM>%. In other embodiments, where a mass being transported on an endless belt atop of a belt contact surface is distributed more uniformly across a lateral width of the belt contact surface, it may be desirable to have the central band Bc cover more or all of the lateral width of the belt contact surface.

When wear plates are manufactured at least partially from a polymer such as UHMWPE or HDPE, and especially when the wear plates are like the wear plates <NUM> that have the ceramic inserts <NUM> inserted in openings thereof along the central band Bc, the belt contact surface <NUM> is more highly resistant to wear from travel of the endless belt <NUM> thereover than without the ceramic inserts <NUM>, thereby enabling the central band Bc to wear at roughly the same rate as the peripheral bands Bp.

As will be appreciated, the size and shape of the ceramic inserts can be varied. <FIG> shows a ceramic insert <NUM> that is circular in form. Ceramic inserts that lack corners or have corners of less acute angles, such as the circular ceramic insert <NUM>, or hexagonal or octagonal ceramic inserts, for example, may be more resistant to fracturing in some scenarios. Further, it can be desirable to use ceramic inserts of a smaller size in some circumstances. While the number of joints in the belt contact surface encountered by an endless belt may increase, the probability of fracturing of the ceramic inserts can decrease.

The dimensions of the cells of the support structure under the belt contact surface can be varied to more evenly distribute the load on the ceramic inserts as vehicles positioned in an endless belt pass thereover.

<FIG> shows a cross-section of a portion of a wear plate <NUM> and a ceramic insert <NUM> in accordance with an alternative embodiment. A horizontal profile of the ceramic insert <NUM> and an opening in the wear plate <NUM> in which the ceramic insert <NUM> is received decreases in size towards a top surface <NUM> of the wear plate <NUM> and the ceramic insert <NUM>. Thus, the dimensions of the opening in the wear plate <NUM> and the ceramic insert <NUM> inhibit upward escape of the ceramic insert <NUM> from the opening when the wear plate <NUM> is positioned at the top of the support structure. As will be appreciated, the opening in the wear plate <NUM> can be dimensioned to define one or more gaps adjacent the ceramic insert <NUM> when the ceramic insert <NUM> is inserted into the opening. These gaps can serve as rinsing system dirt pass-through apertures and/or flooder system apertures.

While, in the above-described embodiments, the inserts are at least partially ceramic, in other embodiments, the inserts are made of any material having a higher resistance to abrasion than the wear plates. As such materials can be more brittle or expensive, it may not be desirable to construct wear plates entirely out of them. By using the materials in a sparing manner, in the form of inserts, the overall effective lifetime of the wear plate can be increased by using the inserts at least where wear otherwise occurs the most in a uniform polymer wear plate. Further, the cost of producing the belt contact surface can be reduced by reducing the amount of the more abrasion-resistant material. Exemplary materials for the inserts can include, for example, stainless steel, aluminum, high-performance plastic, titanium, and ceramic bonded to steel.

<FIG> shows a holddown <NUM> for a wear plate in accordance with another embodiment. The holddown <NUM> is formed by water jet cutting a set of apertures in a polymer wear plate <NUM>. In particular, a central bolt aperture <NUM> is formed, as well as a set of surrounding apertures <NUM>. The surrounding apertures <NUM>, with the bolt aperture <NUM>, define a bolt support ring <NUM> that is supported by four bolt support stays <NUM>. While four bolt support stays <NUM> are used in this embodiment, it will be appreciated that fewer or more bolt support stays can be employed. The bolt support stays <NUM> are non-radial so that depression of the bolt support ring <NUM> relative to a plane of the wear plate <NUM> is possible via tensioning and torqueing of the bolt support stays <NUM>. In other embodiments, the apertures <NUM>, <NUM> can be formed via any other suitable cutting, routing, or molding means.

<FIG> shows a toggle anchor <NUM> that is used in conjunction with the holddown <NUM> of <FIG>. The toggle anchor <NUM> has a pair of plastic rails <NUM>, a first end of each of which is pivotally secured a toggle <NUM>. The toggle <NUM> has a central threaded through hole <NUM>. The rails <NUM> have a set of teeth on their outer surface. When the rails <NUM> are aligned longitudinally, the toggle <NUM> is oriented perpendicularly to a longitudinal axis of the rails <NUM>. A finger grip <NUM> is secured to a second end of each of the rails <NUM>. The finger grips <NUM> have a shape or surface features to enable sliding longitudinal displacement relative to one the other. The rails <NUM> pass through an interior aperture of a retention plate <NUM>. Longitudinal axial displacement of the finger grips <NUM> causes a longitudinal axis of the toggle <NUM> to pivot towards the longitudinal axis of the rails <NUM> to enable the fitting of the toggle <NUM> and the rails <NUM> through the aperture <NUM> of the wear plate <NUM> when the wear plate <NUM> is positioned atop of the set of modular grid panels <NUM>. Once the toggle <NUM> is fitted through the aperture <NUM> and positioned through a cell of one of the modular grid panels <NUM>, the finger grips <NUM> can be realigned axially to cause the toggle <NUM> to pivot towards a perpendicular orientation relative to the longitudinal axis of the rails <NUM>. The toggle anchor <NUM> can then be pulled upward to cause the toggle <NUM> to engage a bottom surface of the modular grid panel <NUM>. The retention plate <NUM> can then be slid down the rails <NUM> towards the bolt support ring <NUM> with some force to pass over the teeth of the rails <NUM> until the retention plate <NUM> abuts against the bolt support ring <NUM> and is held from movement along the longitudinal axis of the rails <NUM> to retain the toggle <NUM> firmly against the modular grid panel <NUM>. The upper portion of the rails <NUM> extending above the retention plate <NUM> can then be snapped off.

<FIG> show the wear plate <NUM> secured to a modular grid panel <NUM> via the toggle anchor <NUM>. The wear plate <NUM>, when positioned atop of the modular grid panel <NUM>, has its holddown <NUM> positioned generally centrally over an open cell <NUM> of the modular grid panel <NUM>. A bolt <NUM> is inserted into the bolt aperture <NUM> and threaded into the threaded through hole <NUM> of the toggle <NUM> to secure the toggle against the modular grid panel <NUM>. As the bolt <NUM> is turned, the holddown <NUM> is deformed, with the bolt support ring <NUM> being pulled towards the toggle <NUM>, thereby deforming the bolt support stays <NUM> and securing the wear plate <NUM> to the modular grid panel <NUM>. The head of the bolt <NUM> becomes recessed below the top plane of the wear plate <NUM>. Rotation of the bolt <NUM> is terminated once the head of the bolt <NUM> sits at least below a maximum wear level <NUM> of the wear plate <NUM>. As the wear plate <NUM> is scheduled to be replaced on or before wearing down of the surface of the wear plate <NUM> to the maximum wear level <NUM>, an endless belt travelling over the wear plate <NUM> should not contact the bolt <NUM>.

<FIG> shows a support deck <NUM> similar to that of <FIG>, wherein a set of wear plates <NUM> similar to those of <FIG>, <FIG>, and <FIG> have been produced with the holddowns <NUM> of <FIG>. The holddowns <NUM> when secured to the modular grid panels <NUM>, exposed in a region where the ceramic inserts <NUM> have not yet been placed in the openings <NUM> of the wear plates <NUM>. The holddown arrangement of <FIG> is particularly useful where it is desired to secure the wear plate <NUM> to the modular grid panels <NUM> between lateral sides of the wear plates <NUM> to avoid shifting and warping thereof. As the bolt support stays <NUM> of the holddowns <NUM> enable some degree of deformation, and as the cells of the modular grid panels <NUM> are somewhat large, expansion of the wear plates <NUM> is permitted.

In other embodiments where the wear plates do not fully span the distance between the edge guides, holddowns like those of <FIG> can be used to hold down the wear plates at least where they are not held down by the edge guides to the modular grid panels or other support structure.

Claim 1:
A conveyor system, comprising:
an endless belt (<NUM>) mounted in a longitudinal direction through a service line (<NUM>), the endless belt (<NUM>) having an upper transport portion adapted to move a wheeled structure (<NUM>) through the service line (<NUM>), and a lower return portion; and
a support deck (<NUM>) positioned below the upper transport portion of the endless belt (<NUM>) to support the endless belt (<NUM>), the support deck (<NUM>) having a belt contact surface (<NUM>) extending along a top of the support deck (<NUM>) and in contact with the upper transport portion of the endless belt (<NUM>), the belt contact surface (<NUM>) being at least partially constructed from a material that is at least partially a polymer, the belt contact surface (<NUM>) having a set of inserts (<NUM>) having a greater abrasion resistance than the material,
characterized in that:
the belt contact surface (<NUM>) comprises a set of wear plates (<NUM>) formed from the material, and each of the set of wear plates (<NUM>) has openings (<NUM>) in which the set of inserts (<NUM>) are received, and wherein a compressible layer (<NUM>) is positioned under the inserts (<NUM>) to facilitate depression of the set of inserts (<NUM>) relative to the set of wear plates (<NUM>).