【発明の詳細な説明】
（１）産業上の利用分野
本発明は、耐摩耗性を有するプーリーに関する．さらに
詳しくは本発明は、土砂、鉱石などを搬送するベルトコ
ンベヤに使用して好適な耐摩耗性プーリーに係る．
（２）従来の技術
ベルトコンベヤによる物体の搬送中、ゴムベルトとコン
ペヤプーリーとの間の滑りに関する問題は、殊に数台の
ベルトコンベヤを連絡して使う長距離搬送に於て深刻で
ある．一白に滑りを生ずると前のベルトコンベヤから運
搬されて来た被運搬物が加わり，負荷が更に増大して搬
送が増々困難になる．
この滑りを防止するために従来，コンベヤプーリーは表
面に硬度の高いゴムを焼き付け，スーパー形Ｊ》るいは
ダブルヘリカル形の溝を加工したいわゆるゴムラフキン
グプーリーが採用された．ゴノ、焼き付けプーリーは乾
燥時には摩擦係数が高く使用上何ら差し支えないが、雨
天時や水分含有率の高い物体を扱う場合にはゴノ、ベル
トと１ーリーとの閏にいわゆる流体潤滑に近い状態が生
じ，摩擦係数が極端に低下して通常の運搬状態を維持す
ることが困難となる．また、土砂、鉱石などの搬送中に
、ゴムベルトとプーリーとの閏にズリや石クズ等の硬い
ものが混入してプーリーのゴム被覆面を損傷、摩耗し，
その傷から肢覆ゴムの創離を生じ、さらにプーリ一面に
錆を生じさせる原因ともなっている．
ゴムベルトと１ーリーとの間の滑りおよび串粍を同時に
防ぐ手段として，近時、ゴム板の内部や表面に金属粒や
セラミック粒またはセラミックタイル等を埋めこんだり
，張りつけたシートを１ーリー表面に接着する方法が実
施されている．（３）発明が解決しようとする課屈
金属粒、セラミック粒やセラミックタイルを内包または
表面に貼りつけたゴムシ一トを接着剤で貼り着けたブー
リーは、ベルトとプーリーとの間の滑りと摩耗に対して
充分なる効果を挙げている．しかしながら、この様なシ
ート状物を貼り着ける方法は、２つの欠点を有している
．その第一はシート材料に制限があることである．シー
トの材質が硬いものではブーリーの曲面に密着させるこ
とができないし、接着効果も芳しくない．従って、シー
ト状物の組成は可とう性材料に限られ、具体的にはゴム
とかウレタンが用いられているに過ぎない．耐酸性を有
する不飽和ポリエステル樹脂、エボキシアクリレート樹
脂、耐水性、耐アルカリ性に優れたエボキシ樹脂等の樹
脂は硬くてゴムやウレタンのような可どう性シートを作
ることは困難である．そのためにプーリーに耐水性、耐
薬品性、耐熱性等の付加的な性能を求められても、従東
のものでは限界があって，付４することができなかった
．
第二の欠点はシートの継ぎ目、合わせ目が存在すること
である．シートをブーリーに貼り着けるには必らず継ぎ
目があり、継ぎ目の接着組成とシート組成とは如何なる
場合にも異なり，長期使用中にその継ぎ目からシートの
剥離の発生、水、薬品その他腐蝕性ガスや物質の浸入に
よる接着剤層やプーリ一本体の腐蝕、発錆が生じ、その
進行によってさらにシートの剥離促進の起こることがわ
かった．
本発明者はこれら従来のブーリーの有する問題点を解決
するために鋭意検討し、本発明に至った．すなわち本発
明の目的は滑り、摩耗を効果的に防ぐことのできる耐摩
耗性ブーリーの提供であり、第二の目的は耐水性、耐薬
品性、耐熱性等を兼ね備えた耐摩耗性プーリーの提供で
あり、他の目的はかかる１−りーの精巧かつ容易な製造
方法にある．
（４》課題を解決するための手段
本発明は熱硬化性樹脂および耐摩耗材からなる耐摩耗性
組成物を１ーリー表面に継ぎ目無しに塗布したのち、註
組成物を硬化させた被覆を有する耐摩耗性ブーリーであ
る．
本発明に使用する熱硬化性樹脂としては特に制限はなく
、例えばウしタン樹脂、エボキシ樹脂、不飽和ポリエス
テル樹脂、エボキシアクリレート樹脂、フラン樹脂、ポ
リイミド樹脂、シリコン樹脂などが挙げられる．なかで
もウレタン樹脂は好ましく、ウレタン樹脂としては一渣
型、二液型の何れも優れる．これらの熱峻化性樹脂は悪
影響の無い範囲内で混合使用することもできる．本発明
に使用する耐摩耗材としては．ｌＮえば衝撃に強い金属
、金属化合物、天然の各種鉱石、各種セラミック等が挙
げられる．特に炭化ケイ素、炭化ホウ素，窒化ゲイ素，
窒化ホウ素、溶解アルミナ、アルミナジルコニア等に代
表される七ラミノク類が好ましく，これらの天然又は人
造の高硬度化自物の砕粒又は焼結，細砕して得られた粉
粒体等が好適に使用することができる．これらの耐摩耗
材は数種併用してもよい．
耐摩耗材の形状について、球状、多面体、円筒体、角柱
体等特に制限されるものではなく、異なる形状、大きさ
のものを併用することもできる．本発明に使用する熱硬
化性樹脂と耐摩耗材の配合割合は通常この種組成物に適
用される耐摩耗材含量が利用され、特別に拘束されるも
のではないが、耐摩耗材の量が少な過ぎては当然耐摩耗
の性能を発揮することができず、反対に多過ぎては樹脂
との結合が腕くなって、耐牽耗性を発揮できなくなるだ
けでなく被覆としての性格を失う．Ｒ体的には樹脂１０
０重量部に対して耐牽耗材１０重菫部乃至１０００重量
部であり、好ましくは５０重呈部乃至６００重量部であ
る．
本発明に使用する耐窄耗組成物の必須有効成分としては
熱硬化性樹脂と耐牽粍材であるが、必要に応じてコロイ
ダルシリ力，有機ベントナイｌ・、水添ヒマシ油、微粒
状炭カル、塩ビパウダー等公知の揺変性付与剤、溶剤、
硬化促進剤、可塑剤、安定剤或いはシランカップリング
剤、チタン力・Ｙ１リング剤等の表面９５理剤、有機ま
たは旭機繊維状物、アルミナ粉、シリカ粉等の充填材、
着色染料顔料、消泡剤、難燃剤、電磁波シール剤、静電
防止剤等の添加剤を耐享粍組成物特性を満足する範囲内
において適宜用いることが出来る．本発明の耐牽粍性プ
ーリーは前述した熱硬化性樹脂と耐孝耗材またはさらに
添加削からなる耐１ク耗組成物をプ一リ一ｋ向に適宜の
方法で継ぎ目無しに塗布し、樹脂を硬化すれば容易に得
られる．耐堂耗組成物は予め熱硬化性樹脂と耐慶耗材と
を混合しておくｊＪ法、またはプーリ一表面に熱硬化性
樹脂を塗布し、該樹脂が硬化しないうちに耐窄耗材を散
布，静電塗布等の適宜の方法により混入させる方法の何
れの場合も有効である．何れの方法に於でも耐中粍組成
物をプーリー而全面に均−に継ぎ目無しに塗布し終るま
では可及的速かに連続作業を行うようにして、耐摩耗組
成物の樹脂硬化の進行差を生ずることをできるだけ防ぐ
よう注意する．
本発明の耐摩粍性１−りーを製逍ずるに当り、耐摩耗材
を熱硬化性樹脂に配合する前に、予め、シランカップリ
ング削７チタンカップリング剤あるいは樹脂、薬液等で
表面処理したり，プラズマエッチング等の物理的表面処
理を施しておくこと、プーリ一表面の錆落し、リン酸処
理、シランカツブリング剤、チタンカップリング剤で処
理しておくこと等も有効な処置である．
さらに必要に応じてブーリ一表面に予めプライマーを塗
布することは本発明の目的達成に好ましい．本発明で用
いられるプライマーは特に限定されるものではなく、公
知の一液型または二液型ブライマーのいずれでらよいが
好ましくはプーリ一表面との接着性がよく、かつ耐窄耗
材ならびに耐摩耗組成物との眉間密着性に優れたものが
よい。DETAILED DESCRIPTION OF THE INVENTION (1) Industrial Application Field The present invention relates to a pulley having wear resistance. More specifically, the present invention relates to a wear-resistant pulley suitable for use in a belt conveyor for conveying earth, sand, ore, etc. (2) Prior Art During conveyance of objects by belt conveyors, the problem of slippage between the rubber belt and the conveyor pulley is particularly serious in long-distance conveyance where several belt conveyors are connected. If slippage occurs, the load from the previous belt conveyor will be added to the conveyor belt, further increasing the load and making conveyance even more difficult. In order to prevent this slippage, conventional conveyor pulleys were so-called rubber luffing pulleys, which had a super-type J or double-helical groove formed by baking hard rubber onto the surface. The gono and baked pulleys have a high coefficient of friction when dry and pose no problem in use, but when it rains or when handling objects with high moisture content, the gonos, belt and pulleys are in a state close to so-called fluid lubrication. This causes an extremely low friction coefficient, making it difficult to maintain normal transportation conditions. Also, during the transportation of earth, sand, ore, etc., hard objects such as scraps and stone chips get mixed into the gap between the rubber belt and the pulley, damaging and abrading the rubber coated surface of the pulley.
The damage causes the limb covering rubber to separate, and is also the cause of rust on the entire pulley surface. Recently, as a means to simultaneously prevent slipping and skewering between the rubber belt and the 1-lead, metal grains, ceramic particles, ceramic tiles, etc. are embedded inside or on the surface of the rubber plate, or sheets pasted on the 1-ley surface. A method of gluing is being implemented. (3) The object of the present invention is to solve the problem of slippage and abrasion between the belt and the pulley. It has been shown to be quite effective. However, this method of pasting sheet materials has two drawbacks. The first is that there are restrictions on sheet materials. If the sheet material is hard, it will not be able to adhere tightly to the curved surface of the booley, and the adhesive effect will not be good. Therefore, the composition of sheet-like materials is limited to flexible materials, specifically rubber and urethane. Resins such as unsaturated polyester resins with acid resistance, epoxy acrylate resins, and epoxy resins with excellent water resistance and alkali resistance are hard and difficult to make into flexible sheets like rubber or urethane. For this reason, even though pulleys were required to have additional performance such as water resistance, chemical resistance, and heat resistance, the Juto's had limitations and could not be achieved. The second drawback is that there are seams and joints between the sheets. There is always a seam when attaching a sheet to a booley, and the adhesive composition at the seam and the sheet composition are different in any case, and the sheet may peel from the seam during long-term use, or it may be exposed to water, chemicals, or other corrosive gases. It was found that the adhesive layer and the pulley itself corrode and rust due to the infiltration of substances and materials, and as this progresses, the sheet peels further. The inventor of the present invention has conducted intensive studies to solve the problems of these conventional booleys, and has arrived at the present invention. That is, an object of the present invention is to provide a wear-resistant pulley that can effectively prevent slipping and wear, and a second object is to provide a wear-resistant pulley that has water resistance, chemical resistance, heat resistance, etc. Another object is to provide an elaborate and easy manufacturing method for such a 1-ree. (4) Means for Solving the Problems The present invention involves applying a wear-resistant composition made of a thermosetting resin and an abrasion-resistant material to the surface of a single-layer without any seams, and then applying a coating made of a hardened composition. The thermosetting resin used in the present invention is not particularly limited, and examples include urethane resin, epoxy resin, unsaturated polyester resin, epoxy acrylate resin, furan resin, polyimide resin, and silicone resin. Among these, urethane resins are preferred, and both one-part type and two-part type are excellent.These thermosetting resins can be mixed and used within the range without adverse effects.In the present invention, Wear-resistant materials to be used include impact-resistant metals, metal compounds, various natural ores, and various ceramics.In particular, silicon carbide, boron carbide, silicon nitride,
Hepta-laminoxes represented by boron nitride, molten alumina, alumina zirconia, etc. are preferable, and powders obtained by crushing, sintering, and pulverizing these natural or artificial highly hardened substances are preferable. It can be used. Several types of these wear-resistant materials may be used in combination. The shape of the wear-resistant material is not particularly limited, such as spherical, polyhedral, cylindrical, prismatic, etc., and materials of different shapes and sizes can be used together. The blending ratio of the thermosetting resin and the wear-resistant material used in the present invention is not particularly restricted, as the content of the wear-resistant material normally applied to this type of composition is not particularly limited. Naturally, it will not be able to exhibit abrasion resistance performance, and on the other hand, if it is too large, the bond with the resin will become weak, and not only will it not be able to exhibit abrasion resistance, but it will also lose its character as a coating. R body is resin 10
The amount of anti-wear material is 10 parts by weight to 1000 parts by weight, preferably 50 parts by weight to 600 parts by weight. The essential active ingredients of the wear-resistant composition used in the present invention are a thermosetting resin and a crush-resistant material. Known thixotropic agents, solvents, such as Cal, PVC powder, etc.
Curing accelerators, plasticizers, stabilizers or silane coupling agents, surface 95 agents such as titanium strength and Y1 ring agents, fillers such as organic or Asahi fibrous materials, alumina powder, silica powder, etc.
Additives such as colored dye pigments, antifoaming agents, flame retardants, electromagnetic wave sealants, and antistatic agents can be used as appropriate within the range that satisfies the corrosion-resistant properties of the composition. The drag-resistant pulley of the present invention is made by applying a wear-resistant composition consisting of the above-mentioned thermosetting resin and a wear-resistant material, or further adding abrasion, to the pulley in an appropriate manner seamlessly. It can be easily obtained by curing. The wear-resistant composition can be prepared using the JJ method, in which a thermosetting resin and a wear-resistant material are mixed in advance, or by applying a thermosetting resin to one surface of the pulley and spraying the wear-resistant material before the resin hardens. Any method of mixing using an appropriate method such as electrostatic coating is also effective. In either method, the process is continued as quickly as possible until the wear-resistant composition is applied evenly and seamlessly over the entire surface of the pulley, and the resin hardening of the wear-resistant composition is continued. Be careful to avoid discrepancies as much as possible. When manufacturing the wear-resistant 1-reed of the present invention, before blending the wear-resistant material with the thermosetting resin, the surface may be treated with a silane coupling agent, a resin, a chemical solution, etc. Effective measures include physical surface treatment such as plasma etching, rust removal from the pulley surface, phosphoric acid treatment, and treatment with a silane coupling agent or titanium coupling agent. Furthermore, it is preferable to apply a primer to the surface of the boule in advance, if necessary, in order to achieve the object of the present invention. The primer used in the present invention is not particularly limited, and may be any known one-component or two-component primer, but preferably one that has good adhesion to the surface of the pulley, is a wear-resistant material, and is abrasion-resistant. It is preferable that the composition has excellent adhesion to the glabella.
例えば、二液型エボキシ樹脂系プライマー、一液型の湿
気硬化型ウレタン樹脂系プライマー、変性シリコン系ブ
ライマー、フェノキシ樹脂系１ライマー等が挙げられる
．これらのブライマーの塗布量は、特に制限されないが
通常約３０〜５００ｇ／ｗｉである．
本発明の耐窄耗性ブーリーは耐摩耗組成物の表面上に必
要に応じてさらにトツブコートを塗布してもよく、本発
明効果を助長されるものである．本発明の耐摩耗性プー
リーは広＜ー，般に伝動ベルト用駆動プーリーとしても
使えるが、人容菫ベルトコンベヤ用ブー９一に好適であ
り，ドライブプーリー、ヘッドプーリー，テールプーリ
ー，テンションプーリー等に適し，最適にはスナツアブ
ーリー ベンド１−り−である．この池にアイドラー、
リターンローラー等にら同じように使うことができる．
（５）本発明の作用効果
本発明耐摩耗性ブーリーは耐摩耗組成物を塗布するだけ
であるので、従来の耐摩耗シートを貼る場合に比較して
作業性容易かつ表面に確実に密着した被覆が得られ、無
駄が無く、経済的でもある．また、シート貼り着けのよ
うな継ぎ目が全く無いので、被覆の剥離が無く、水、薬
品、腐蝕性ガスや物体の浸入することも無い．従って長
時間の使用に供することができ、ベルトの滑り、ブーリ
ーの摩耗が確実に防止することができるようになったこ
とはこの種産業界に寄与する意義が大である．さらに，
機能の異なる耐伊耗組成物を塗り重ねることが出来るの
で耐摩耗性、防滑のみならず耐水、耐薬、耐熱等の作業
環境に対する適応性を同時に付与することができるよう
になった．以下に本発明の耐摩耗性ブーリーを実施例に
より詳述するが、本発明はこれら実施例により何ら制限
されるものではない．
χ施例１
幅１０００膿，直径５００−のサンドプラストされたプ
ーリ一表面に，プライマーとしてサントープライマーＰ
Ｅ（三東化工業（株》製品名，エボキシ樹脂系プライマ
ー）を１５０ｇ／ｉの割合で八ケ塗りし，２時間後にサ
ントーライニング“レジセラＳＺ−Ｅ” く三東化工業
（株》製品名、セラミック人りエボキシ樹脂系耐摩耗性
ライニング剤》の主剤７／硬化剤を５．，’１．（重量
比》の割合で混合したパテ状の組成物をコテで均一・に
５一厚みに継ぎ目を生じないよう注意しながら速やかに
塗布した．次いで温度４０でで５時間保持して組成物を
硬化させた．塗布作業中，パテ状の組成物がプーリ一面
からダレるようなことは無かったが．プーリーをゆっく
りと回転させることによー〕でダレ防止に注意した．
このようにして得られた耐摩耗性プーリーに幅９００−
のベルトをつけ、ベルト速度毎分１３５ｍとなるように
運転しながら次の二種類の試験を行いプーリーの性能評
価を得た．
（１）けい砂および粘度を含んだ泥水をベルトとプーリ
ーの間に滴下しながら、運転、停止を１０００回縁り返
えし、ベルトの滑りを［ｌ！察した．ベルトスリップは
認められなかった。Examples include two-component epoxy resin primer, one-component moisture-curable urethane resin primer, modified silicone primer, and phenoxy resin one-component primer. The amount of these brimers to be applied is not particularly limited, but is usually about 30 to 500 g/wi. In the abrasion-resistant booley of the present invention, a totube coat may be further applied on the surface of the abrasion-resistant composition, if necessary, to enhance the effects of the present invention. The wear-resistant pulley of the present invention can generally be used as a drive pulley for power transmission belts, but it is also suitable for belt conveyors such as drive pulleys, head pulleys, tail pulleys, tension pulleys, etc. Suitable for this, and the most suitable is Snatsuaburi Bend 1-ri-. Idler in this pond
Return rollers, etc. can be used in the same way. (5) Effects of the present invention Since the wear-resistant booley of the present invention is simply coated with a wear-resistant composition, it is easier to work with than when pasting a conventional wear-resistant sheet, and the coating adheres reliably to the surface. is obtained, there is no waste, and it is also economical. Additionally, since there are no seams like when pasting sheets, there is no peeling of the coating, and no infiltration of water, chemicals, corrosive gases, or objects. Therefore, the fact that it can be used for long periods of time and that belt slippage and booley wear can be reliably prevented is a significant contribution to this type of industry. moreover,
Since it is possible to layer wear-resistant compositions with different functions, it is now possible to simultaneously impart not only wear resistance and anti-slip properties, but also adaptability to the work environment such as water resistance, chemical resistance, and heat resistance. The wear-resistant booley of the present invention will be explained in detail below with reference to Examples, but the present invention is not limited to these Examples in any way. χ Example 1 Santo Primer P was applied as a primer to the surface of a sandblasted pulley with a width of 1000 mm and a diameter of 500 mm.
Apply eight coats of E (Santo Kakogyo Co., Ltd. product name, epoxy resin primer) at a rate of 150 g/i, and after 2 hours apply Santo Lining "Regicera SZ-E" Santo Kakogyo Co., Ltd. product name, A putty-like composition prepared by mixing the main ingredient 7 of the ceramic epoxy resin wear-resistant lining agent and the hardening agent in a ratio of 5. and 1. The composition was applied quickly while being careful not to cause any damage.Then, the composition was cured by holding at a temperature of 40°C for 5 hours.During the application process, the putty-like composition did not sag from the entire surface of the pulley. However, care was taken to prevent sagging by rotating the pulley slowly.The wear-resistant pulley thus obtained was
The following two types of tests were conducted to evaluate the performance of the pulley, with a belt attached and the belt running at a belt speed of 135 m/min. (1) While dropping muddy water containing silica sand and viscosity between the belt and the pulley, start and stop the belt 1000 times to prevent the belt from slipping [l! I guessed it. No belt slip was observed.
（２）砂をベルトとプーリーのｒ：ａ４こ散布しながら
１５００時間運転したのち，プーリ一表面を観察した．
樹脂の表面部に押し込み摺り傷は認められるが、セラミ
ックの摩耗、剥離、塗布層の利Ｍ等は無かった．
＼実施例２
幅１１５０■、直径６００ｍのサンドプラストされたフ
゜−り一表血に、サントーライニング＃３ １ ０ （
三東化工業（株）製品名、熱硬化性ウレタン樹脂系ライ
ニング剤》の主剤／硬化剤を４．．／１（重量比｝で混
合した樹脂液３０重量部に対しジルコニア系セラミノク
砂７０重菫部を速かに均−に混合したものをコテで均−
に５−厚みに継ぎ目を生じないよう注意しながら速かに
塗布した．次いで温度４０℃で３時間保持して組成物を
硬化させた．塗布作業中、組成物がプーリー向からダレ
ることの無いようにプーリーをゆっくりと回転させた．
このようにして得られた耐摩耗性プーリーに幅１． ０
５ ０鵬のベルトをつけ、毎分１３５ｍのベルｌ・速
度で運転しながら、文施ＶＡｌと同じ試験を行って性能
を評価した。ベルｌ一のスリツアおよびライ二冫グ層の
摩耗、剥離は認められなかった。(2) After operating for 1500 hours while spreading sand on the belt and pulley R:A4, the surface of the pulley was observed.
Although indentation scratches were observed on the surface of the resin, there was no abrasion or peeling of the ceramic, and no damage to the coating layer. \Example 2 Santo lining #3 10 (
4. Add the main ingredient/curing agent of Santo Kakogyo Co., Ltd. product name, thermosetting urethane resin lining agent. ．． 70 parts by weight of zirconia ceramic sand was quickly and evenly mixed with 30 parts by weight of the resin liquid mixed at a ratio of 1/1 (weight ratio).
5- Apply quickly, being careful not to create seams in the thickness. The composition was then cured by holding at a temperature of 40°C for 3 hours. During the application process, the pulley was rotated slowly to prevent the composition from dripping from the pulley. The wear-resistant pulley thus obtained has a width of 1. 0
The performance was evaluated by performing the same tests as the Wenshi VAl while operating at a speed of 135 m/min with a 50 mm belt. No abrasion or peeling of the slits and second layer of the bell was observed.
比較ＰＡ１
実施ｆＩＡ１に用いたと同様のブーリーに、５一厚の硬
質ゴムラッキングした．表面はダブルヘリカル形講加工
した．このラッキングプーリーを実施例１と同じ試験を
実施したところ、ベルトのスリップおよびゴムの摩耗の
何れも激しかった．比較例２
実施例２に用いたと同様の１ーリーに、硬質ゴム板にセ
ラミックタイルを焼付けたラッキング板（５■厚）を接
着剤で接合し、た．
このラッキングプーリーを実施例１と同じ試験を実施し
たところ、ベルトのスリップが認められた．セラミック
タイルの摩耗は認められないが、セラミックの剥離があ
り、特にラッキング板の継ぎ目の一部が剥離し、その部
分のセラミックの剥離、ゴムの摩耗が認められた．
特許出願人 三東化工業株式会社Comparison PA1 A booley similar to that used in implementation fIA1 was coated with a 51-thick hard rubber rack. The surface is processed into a double helical shape. When this racking pulley was subjected to the same tests as in Example 1, both belt slip and rubber wear were severe. Comparative Example 2 A racking board (5 mm thick), which was a hard rubber board with ceramic tiles baked onto it, was bonded to a one-liner similar to that used in Example 2 with an adhesive. When this racking pulley was subjected to the same test as in Example 1, belt slip was observed. Although no wear was observed on the ceramic tiles, there was some peeling of the ceramic, especially at the joints of the racking plates, and peeling of the ceramic and abrasion of the rubber in that area were observed. Patent applicant Santo Kakogyo Co., Ltd.