US3876579A - Composition to be applied to a surface to increase its wear resistance - Google Patents

Composition to be applied to a surface to increase its wear resistance Download PDF

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Publication number
US3876579A
US3876579A US238183A US23818372A US3876579A US 3876579 A US3876579 A US 3876579A US 238183 A US238183 A US 238183A US 23818372 A US23818372 A US 23818372A US 3876579 A US3876579 A US 3876579A
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United States
Prior art keywords
particles
composition
order
abrasion resistant
resin
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US238183A
Inventor
James R Hallstrom
Raymond J Hoffman
Ronald L Walling
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FEL-PRO CHEMICAL PRODUCTS LP
Wilmington Trust Co
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Rexnord Inc
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Priority to US238183A priority Critical patent/US3876579A/en
Priority to ZA731080A priority patent/ZA731080B/en
Priority to CA164,201A priority patent/CA1010178A/en
Priority to AU52440/73A priority patent/AU475569B2/en
Priority to DE2311507A priority patent/DE2311507C3/en
Priority to SE7303825A priority patent/SE404018B/en
Priority to BE129087A priority patent/BE797127A/en
Priority to NL7304013.A priority patent/NL163552C/en
Priority to FR7310746A priority patent/FR2178644A5/fr
Priority to ES413001A priority patent/ES413001A1/en
Priority to GB1464473A priority patent/GB1431676A/en
Priority to BR732177A priority patent/BR7302177D0/en
Priority to JP48034215A priority patent/JPS527449B2/ja
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Publication of US3876579A publication Critical patent/US3876579A/en
Priority to US06/182,031 priority patent/USRE30691E/en
Assigned to WADE, WILLIAM J., RODNEY SQUARE NORTH, WILMINGTON DELAWARE 19890, TRUSTEE, WILMINGTON TRUST COMPANY, RODNEY SQUARE NORTH, WILMINGTON DELAWARE 19890, A CORP. OF DE. reassignment WADE, WILLIAM J., RODNEY SQUARE NORTH, WILMINGTON DELAWARE 19890, TRUSTEE SECURITY INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: REXNORD INC.
Assigned to CHEMREX INC., 1209 ORANGE STREET, WILMINGTON, DELAWARE 19801 A DE CORP. reassignment CHEMREX INC., 1209 ORANGE STREET, WILMINGTON, DELAWARE 19801 A DE CORP. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: REXNORD, INC.
Assigned to WILMINGTON TRUST COMPANY AND WADE, WILLIAM J., AS TRUSTEE reassignment WILMINGTON TRUST COMPANY AND WADE, WILLIAM J., AS TRUSTEE ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: CHEMEX INC., A CORP. OF DE
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Assigned to FEL-PRO INCORPORATED reassignment FEL-PRO INCORPORATED ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: CHEMREX, INC.
Assigned to FEL-PRO CHEMICAL PRODUCTS L.P. reassignment FEL-PRO CHEMICAL PRODUCTS L.P. ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: FEL-PRO INCORPORATED
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B05SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05DPROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D5/00Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
    • B05D5/02Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures to obtain a matt or rough surface
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B24GRINDING; POLISHING
    • B24DTOOLS FOR GRINDING, BUFFING OR SHARPENING
    • B24D3/00Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents
    • B24D3/34Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties
    • B24D3/342Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties incorporated in the bonding agent
    • B24D3/344Physical features of abrasive bodies, or sheets, e.g. abrasive surfaces of special nature; Abrasive bodies or sheets characterised by their constituents characterised by additives enhancing special physical properties, e.g. wear resistance, electric conductivity, self-cleaning properties incorporated in the bonding agent the bonding agent being organic
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/18Cold vulcanisation
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C41/00Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/12Spreading-out the material on a substrate, e.g. on the surface of a liquid
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B26/00Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02Macromolecular compounds
    • C04B26/10Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/14Polyepoxides
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09DCOATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D7/00Features of coating compositions, not provided for in group C09D5/00; Processes for incorporating ingredients in coating compositions
    • C09D7/40Additives
    • C09D7/60Additives non-macromolecular
    • C09D7/61Additives non-macromolecular inorganic
    • C09D7/62Additives non-macromolecular inorganic modified by treatment with other compounds
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2063/00Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/16Fillers
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/32Wheels, pinions, pulleys, castors or rollers, Rims
    • B29L2031/324Rollers or cylinders having an axial length of several times the diameter, e.g. embossing, pressing or printing
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482Coating or impregnation materials
    • CCHEMISTRY; METALLURGY
    • C08ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08KUse of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K9/00Use of pretreated ingredients
    • C08K9/02Ingredients treated with inorganic substances

Definitions

  • An object of this invention is an abrasive resistant coating for application on practically any surface subject to wear regardless of its location.
  • Another object is such a coating using conventional tools and procedures.
  • Another object is an abrasive resistant coating which will conform to the surface to which it is applied.
  • Another object is a wearing composition which may be installed on the job and yet provides a hard wearing surface for areas of severe wear.
  • Another object is a trowelable composition which quickly hardens to provide a surface having high resistance to abrasion.
  • Another object is a wear resistant composition which can be applied to irregular surfaces such as those found in cones, elbows. etc.
  • Another object is an abrasive resistant coating having a secondary abrasive filler of a hardness on the order of that of the material causing the wear.
  • Another object is an abrasive resistant coating which has a fairly long working life in its mixed stage permitting adequate time to trowel it into difficult to reach or large areas. yet which will cure in a relatively short timev
  • Another object is an abrasive resistant coating that is more resistant to wear than Ni-Hard iron.
  • Another object is an abrasive resistant coating having a resistance to wear approaching that of ceramic tile.
  • Another object is an abrasive resistant material that also functions as a corrosion inhibiting coating.
  • Another object is an abrasive resistant coating which contains alumina ceramic particles.
  • Another object is an abrasive resistant coating containing alumina ceramic particles which is mixed on the job and in which the particles will not settle out while the composition hardens.
  • Another object is an abrasive resistant material of the above type that will not settle out in the can.
  • FIG. I is a side view. in section, through a typical application in a diagrammatic or schematic representation.
  • FIG. 2 is a portion of FIG. 1 on an enlarged scale.
  • This invention is directed to an abrasive resistant surfacing for machinery and wearing surfaces on the job. This is accomplished by use of a composition having high alumina ceramic particles and a co-abrasive filler of smaller particles which are about as hard as the material causing the wear.
  • the particles and filler are contained in components which may be mixed together on the job to provide a substance that can be applied by troweling or similar methods to the surface to be protected or repaired.
  • the abrasive resistant coating when mixed has a paste-like consistency which enables it to be applied and to conform to any shape such as cones, elbows and other curved surfaces.
  • the paste-like mixture cures rapidly. permitting the surface to be put back into operation quickly.
  • the coating could have a working life of on the order of 30-45 minutes at 68F, which allows ample time to trowel the material onto difficult to reach or large surfaces. It will cure for use in 3-l6 hours at 70F.
  • curing time can be reduced by heating metal surfaces to hand warmth or warmer before or after applying the composition. This will reduce the curing or hardening time to. say. approximately l hour.
  • a composition of this invention may take many different forms.
  • a base or substrate 10 has been shown which may be assumed to be a worn-out part. such as a liner. chute or what-have-you.
  • a coating or composition I2 is superimposed on the surface thereof and. as shown in FIG. 2, in a somewhat schematic or diagrammatic manner.
  • the coating includes a matrix or base substance or bonding agent 14 containing and holding in place large abrasive resistant particles I6 at suitable intervals with smaller abrasive filler particles I8 in the matrix and interposed between and around the larger beads or chips.
  • the matrix material which may be a polymer.
  • the matrix itself which may include the resin and a thixotropic agent. when mixed and adhering to the surface. acts as a cushion for the large abrasive resistant particles.
  • the co-abrasive or secondary filler particles I8 are of a much smaller size than the primary abrasive resistant particles 16 and these smaller particles fill the voids or interstices between the large abrasive particles.
  • the co-abrasive filler 18 protects the polymer matrix I4 from being worn away from the abrasive resistant particles. As a result, the abrasive resistant particles remain in place in the matrix longer providing a longer wearing surface.
  • the abrasive resistant particles and co-abrasive filler are maintained in suspension in the polymer matrix during mixing and curing operations by means of a thixotropic agent.
  • a co-abrasive filler found to function particularly well in a wearing composition in accordance with this invention may be silicon carbide, 180 mesh size.
  • other fillers may be used as long as they are about as hard as the material being handled, in other words, the material causing the wear on the surface being protected.
  • the following substances may be used as fillers:
  • the cost of the wearing composition used in connection with the method of this invention may be reduced by matching the co-abrasive filler to the material causing wear.
  • the co-abrasive filler may be used as the co-abrasive filler.
  • the composition of the matrix holding the large abrasive resistant particles in position may vary over a wide range.
  • many types of polymers may be used, such as: epoxide polymers; unsaturated polyester (carboxylate-glycol adduct); a polyurethane; a polyimide or polyamide resin or the like.
  • a particular polymer found to function particularly well as the matrix is an epoxy resin containing a thixotropic agent which resin is cured by means of a mixed polyamine/polyamide curing agent.
  • the thixotropic agent used is a pure CALlDRlA asbestos sold under the designation RG- 144 by Union Carbide Corporation.
  • Other agents might be Bentonite, fumed silica, M-P-A by Baker Caster Oil, polyacrylamide and so forth.
  • the composition of this invention it has been found desirable to provide the large abrasive resistant particles and the co-abrasive filler in both the resin and curing components of the epoxy resin composition.
  • the purpose of doing this is two-fold. First, it provides a mixing ratio between the resin and curing components of approximately 2 to 1 whether the components are measured by weight or volume. Second, it provides thorough wetting of all the abrasive particles and coabrasive filler. A thorough wetting of these materials is difficult to obtain if the materials are provided in only one of the two components.
  • a specific example of a suitable composition for use in this invention is:
  • the resin may be supplied in one can and the curing agent in another, the two being sold together with the resin can being, for example, a l-gallon container and the curing components being in a onehalf-gallon can.
  • a l-gallon container for the resin
  • the one-half-gallon can for the curing agent has been found convenient. In such a situation a proportion of the amounts would be emptied from each and thoroughly mixed before application to the surface to be protected. And, if all of the resin and curing agents in the two-can kit are not used at once, the cans may be sealed up and used later.
  • Another example of a suitable composition is as follows:
  • the above composition is believed to have the advantage of better viscosity control.
  • Another example of a suitable composition is as follows:
  • Silicon Carbide. I80 X. Simonds This example is believed to have the advantage of longer term shelf stability and would be suitable for uses or applications that require such.
  • the large particles and co-abrasive filler are in a ratio of on the order of 4 to I, while the particles (both large particles and co-abrasive filler) and matrix (resin, curing agent, etc.) are in a ratio on the order of 3 to I.
  • the wearing composition may be applied or used on any one of a number of parts or surfaces.
  • Good examples are feed chutes, buckets. hoppers, feed plates, pipe and elbows. side plates, diverter plates, discharge chutes and skirts, sand slinger, and the feed spout of grinding mills. It might also be used on trunnion liners, pump casing, return idlers, screens, dust collectors and cyclones and the like.
  • the above are merely examples and it should be understood that other applications are important, such as the hard surfacing of classifier flights and shoes, the drums of cement trucks, fan blades, the surfacing of pan feeders, cobbler repulp circulators, the buckets and teeth of front end loaders, and so forth.
  • the large abrasive resistant particles have been stated as being high alumina ceramic particles, but a number of other particles could be used, such as boron nitride, tungsten carbide, silicon carbide, boron carbide and the like.
  • the large particles have been shown as generally round or spherical. But, in certain situations, chips might be used. Round particles may be used for a trowelable mix, but in certain applications, chips might be used. For example, if the composition is to be applied or cast, chips would not be objectionable and they might be less expensive. In certain situations, chips could be used in a trowelable mixture. This is particularly true in a casting system where different beads would be appropriate.
  • a trowelable wearing composition for on-the-job application to a surface to provide a wearing surface having more resistance to wear caused by impact, abrasion, erosion or corrosion than NiHard iron including a matrix composed of an uncured curable crosslinkable thermosetting resin, a curing agent for the resin and a thixotropic agent, large abrasion resistant ceramic particles on the order of one-sixteenth inch in their largest dimension, much smaller co-abrasion resistant filler particles on the order of 180 mesh size and of a hardness on the order of that of the material causing the wear dispersed in rather random fashion among the large particles when applied, the ceramic and filler particles being in a ratio on the order of 4 to l by weight, and the particles and matrix being in a ratio on the order of 3 to l by weight.
  • composition of claim I further characterized in that the large abrasion resistant particles are metal coated alumina ceramic particles.
  • composition of claim 1 further characterized in that the large ceramic particles are essentially spherical beads.
  • composition of claim I further characterized in that the co-abrasion resistant filler is silicon carbide.
  • thermosetting resin is an epoxy resin
  • a curable resin composition for on-the-job application to a surface to provide a wearing surface having more resistance to wear than NiHard iron a unitary system including a container of a certain amount of the uncured resin with large abrasion resistant ceramic particles on the order of one-sixteenth inch in their largest dimension and much smaller co-abrasion resistant filler particles on the order of I mesh size therethrough and of a hardness on the order of that of the material causing the wear, and a separate container with a proportionate amount of a curing agent and with large abrasion resistant ceramic particles on the order of one-sixteenth inch in their largest dimension and much smaller co-abrasion resistant filer particles on the order of I80 mesh size therethrough whereby the contents of both containers are capable of mixing readily by the existence of large and much smaller abrasive particles in each container, the ceramic and filler particles being in a ratio on the order of 4 to I by weight and the particles and resin plus curing agent being in a ratio on the order of 3 to l by weight
  • composition of claim 6 further characterized in that the smaller co-abrasion resistant filler particles in that the large abrasion resistant ceramic particles are are Silicon carbide metal coated alumina ceramic particles.
  • composition of claim 6 further characterized in that the large ceramic particles are spherical beads.
  • the resin is an epoxy resin.

Abstract

A coating having high resistance to wear caused by impact, abrasion, erosion and corrosion. A trowelable composition containing high alumina ceramic particles and a co-abrasive filler of smaller particles of inorganic and/or metallic origin in a polymer matrix for application to a surface to be repaired or protected.

Description

O United States Patent 1191 1111 3,876,579 Hallstrom et al. 1 1 Apr. 8, 1975 1 1 COMPOSITION TO BE APPLIED To A 3003.798 10/1961 Sandlin 260/37 EP x SURFACE o INCREASE ITS WEAR 3.033.088 5/1962 Winenwyler 260/37 EP X 3.041.156 6/1962 Rowse et a1. 51/298 RESISTANCE 31081803 4/1963 Bakian..... 51/298 [75] Inventors: James R. Hallstrom, Brookfield; 3.183.633 5/1965 Decker 51/298 X Raymond Hoffman, Fox p 3.205.054 9/1965 Tucker 51/298 R l L w ni Sussex. a" of 3,225,495 12/1965 de Vries 51/298 X Wis 3.277.052 10/1966 Thompson et a1. 260/37 EP X 3.360.391 12/1967 Richtzenhain et a1. 260/37 EP X [73] Assignee: Rexnord Inc., Milwaukee, Wis. 3.383,]91 5/1968 Thomas 51/298 3.469.959 9/1969 Stein 51/298 1221 Hedi 1972 3.502.453 3/1970 Baratta 51/298 N01 3.524.286 8/1970 Wahrer 51/298 Primary Examiner-Donald E. Czaja US. Cl. EP; Ass/31a," E anliner s Person [51] Int. Cl C08g 51/04 Almrney, Agent, or Firm-Kinzer, Plyer. Dorn & [58] Field of Search 260/37 EP; 51/298 MgEac-hran [56] References Cited [57] ABSTRACT UNITED STATES PATENTS A coating having high resistance to wear caused by 2.162.600 6/1939 Bull 51/298 X impact, abrasion. erosion and corrosion. A trowelable 3 9/1940 Bull 51/298 X composition containing high alumina ceramic particles 2 7691199 PZIICh and a co abrasive filler of maller particles of ino c f t 2 32 ganic and/0r metallic origin in a polymer matrix for oep er 2.943.953 7/1960 Daniel 260/37 E? x "ppl'camn surface to be repa'red pmteced' 2.949.351 8/1960 Vigliaturu 51/298 10 Claims, 2 Drawing Figures COMPOSITION TO BE APPLIED TO A SURFACE TO INCREASE ITS WEAR RESISTANCE SUMMARY OF THE INVENTION This invention is concerned with on-the job installation of an abrasive resistant coating and a composition therefore.
An object of this invention is an abrasive resistant coating for application on practically any surface subject to wear regardless of its location.
Another object is such a coating using conventional tools and procedures.
Another object is an abrasive resistant coating which will conform to the surface to which it is applied.
Another object is a wearing composition which may be installed on the job and yet provides a hard wearing surface for areas of severe wear.
Another object is a trowelable composition which quickly hardens to provide a surface having high resistance to abrasion.
Another object is a wear resistant composition which can be applied to irregular surfaces such as those found in cones, elbows. etc.
Another object is an abrasive resistant coating having a secondary abrasive filler of a hardness on the order of that of the material causing the wear.
Another object is an abrasive resistant coating which has a fairly long working life in its mixed stage permitting adequate time to trowel it into difficult to reach or large areas. yet which will cure in a relatively short timev Another object is an abrasive resistant coating that is more resistant to wear than Ni-Hard iron.
Another object is an abrasive resistant coating having a resistance to wear approaching that of ceramic tile.
Another object is an abrasive resistant material that also functions as a corrosion inhibiting coating.
Another object is an abrasive resistant coating which contains alumina ceramic particles.
Another object is an abrasive resistant coating containing alumina ceramic particles which is mixed on the job and in which the particles will not settle out while the composition hardens.
Another object is an abrasive resistant material of the above type that will not settle out in the can.
Other objects may be found in the following specification, claims, and drawings.
FIG. I is a side view. in section, through a typical application in a diagrammatic or schematic representation; and
FIG. 2 is a portion of FIG. 1 on an enlarged scale.
DESCRIPTION OF THE PREFERRED EMBODIMENT This invention is directed to an abrasive resistant surfacing for machinery and wearing surfaces on the job. This is accomplished by use of a composition having high alumina ceramic particles and a co-abrasive filler of smaller particles which are about as hard as the material causing the wear. The particles and filler are contained in components which may be mixed together on the job to provide a substance that can be applied by troweling or similar methods to the surface to be protected or repaired.
The abrasive resistant coating when mixed has a paste-like consistency which enables it to be applied and to conform to any shape such as cones, elbows and other curved surfaces. The paste-like mixture cures rapidly. permitting the surface to be put back into operation quickly. The coating could have a working life of on the order of 30-45 minutes at 68F, which allows ample time to trowel the material onto difficult to reach or large surfaces. It will cure for use in 3-l6 hours at 70F. When necessary. curing time can be reduced by heating metal surfaces to hand warmth or warmer before or after applying the composition. This will reduce the curing or hardening time to. say. approximately l hour.
A composition of this invention may take many different forms. In the drawing, a base or substrate 10 has been shown which may be assumed to be a worn-out part. such as a liner. chute or what-have-you. A coating or composition I2 is superimposed on the surface thereof and. as shown in FIG. 2, in a somewhat schematic or diagrammatic manner. the coating includes a matrix or base substance or bonding agent 14 containing and holding in place large abrasive resistant particles I6 at suitable intervals with smaller abrasive filler particles I8 in the matrix and interposed between and around the larger beads or chips. The matrix material, which may be a polymer. bonds to the surface of the part 10 to be protected and holds the larger abrasive resistant particles 16 in position in relation thereto and in relation to each other and also holds the co-abrasive filler particles 18 in a random dispersion throughout the matrix and in position to take the wear. The matrix itself which may include the resin and a thixotropic agent. when mixed and adhering to the surface. acts as a cushion for the large abrasive resistant particles. Dur ing impact of the material causing wear. such as the various types of ores, sand. gravel. etc., energy is transmitted to the matrix from the particles and is dissipated. This prevents cracking and breaking of the more brittle large abrasive resistant particles.
In such a composition, the co-abrasive or secondary filler particles I8 are of a much smaller size than the primary abrasive resistant particles 16 and these smaller particles fill the voids or interstices between the large abrasive particles. The co-abrasive filler 18 protects the polymer matrix I4 from being worn away from the abrasive resistant particles. As a result, the abrasive resistant particles remain in place in the matrix longer providing a longer wearing surface. The abrasive resistant particles and co-abrasive filler are maintained in suspension in the polymer matrix during mixing and curing operations by means of a thixotropic agent.
While many polymers, abrasive resistant particles. co-abrasive fillers and thixotropic agents may be found suitable for a composition to be used in this invention. a more specific and particularly desirable composition is obtained by the use of high alumina ceramic beads as the abrasive resistant particles. More specifically. the use of metal coated alumina ceramic particles of the type sold by Coors Porcelain Company of Golden. Colorado under the trademark METLX has been found to produce an outstanding abrasive resistant coating. This ceramic is a high alumina type) which has very fine grain (crystal) boundaries to give good abrasive resistance. A coating of metal is placed on the surfaces of ceramic particles. It has been found that polymers and other matrices bond better to the metal coating than they do directly to ceramic. The particles used may be on the order of a fraction of an inch, for example approximately one sixteenth of an inch, in their largest dimension.
A co-abrasive filler found to function particularly well in a wearing composition in accordance with this invention may be silicon carbide, 180 mesh size. However, other fillers may be used as long as they are about as hard as the material being handled, in other words, the material causing the wear on the surface being protected. By way of example, but not of limitation, the following substances may be used as fillers:
Diamond dust, boron carbide, boron nitride, tungsten carbide, alumina ceramic, silica sand, taconite,
etc.
The cost of the wearing composition used in connection with the method of this invention may be reduced by matching the co-abrasive filler to the material causing wear. For example, where sand is the abrasive material causing the wear, silica sand or silica flour may be used as the co-abrasive filler.
The composition of the matrix holding the large abrasive resistant particles in position may vary over a wide range. For example, many types of polymers may be used, such as: epoxide polymers; unsaturated polyester (carboxylate-glycol adduct); a polyurethane; a polyimide or polyamide resin or the like. A particular polymer found to function particularly well as the matrix is an epoxy resin containing a thixotropic agent which resin is cured by means of a mixed polyamine/polyamide curing agent. The thixotropic agent used is a pure CALlDRlA asbestos sold under the designation RG- 144 by Union Carbide Corporation. Other agents might be Bentonite, fumed silica, M-P-A by Baker Caster Oil, polyacrylamide and so forth.
In the composition of this invention, it has been found desirable to provide the large abrasive resistant particles and the co-abrasive filler in both the resin and curing components of the epoxy resin composition. The purpose of doing this is two-fold. First, it provides a mixing ratio between the resin and curing components of approximately 2 to 1 whether the components are measured by weight or volume. Second, it provides thorough wetting of all the abrasive particles and coabrasive filler. A thorough wetting of these materials is difficult to obtain if the materials are provided in only one of the two components.
A specific example of a suitable composition for use in this invention is:
Resin Component Parts by Weight "EPON" Resin 3224. Shell Curing Component Parts by Weight Jefferson AL- 1, Jefferson Chemical Company l0.0 Vanamid 50-40. R. T. Vanderbilt Company 10.0 Asbestos, "RG- l44". Union Carbide Corporation 2.0 Silicon Carbide, 180 X, Simonds Abrasive Div.. The Wallace Murray Corp. 21.7
-Continued Coors METLX" Pellets in this example the resin may be supplied in one can and the curing agent in another, the two being sold together with the resin can being, for example, a l-gallon container and the curing components being in a onehalf-gallon can. This is merely an example and it should be understood that any suitable sizes could be used depending upon the needs of the customer and the amount of material to be used in an application. But a l-gallon can for the resin and the one-half-gallon can for the curing agent has been found convenient. In such a situation a proportion of the amounts would be emptied from each and thoroughly mixed before application to the surface to be protected. And, if all of the resin and curing agents in the two-can kit are not used at once, the cans may be sealed up and used later.
The above example, when mixed, applied, and cured, has the following characteristics:
Tensile Strength 4,000 psi Compressive Strength 15,000 psi Heat Deflection Temperature [95F Lap Shear Strength 2,000 psi Gel Time 90 min. Working Time 30 min. at F.
Another example of a suitable composition is as follows:
Resin Component Parts by Weight Curing Component Parts by Weight Jefferson AL- 1 Jefferson Chemical Company 10.0 Versamid 140, General Mills 10.0 Asbestos, "RC-144, Union Carbide Corporation 1.0 Silicon Carbide, I X, Simonds Abrasive Div. The Wallace Murray Corp. 21.7 Coors METLX" Pellets 70.0
The above composition is believed to have the advantage of better viscosity control.
Another example of a suitable composition is as follows:
Resin Components Parts by Weight EPON 8280, Shell Chemical Corporation 50.0 Asbestos, "RG-l44, Union Carbide Corporation 2.5
TiO,, "TTTANO National Continued Resin Components Parts by Weight Lead Co. L5
Silicon Carbide. I80 X. Simonds This example is believed to have the advantage of longer term shelf stability and would be suitable for uses or applications that require such.
Another example is as follows:
Resin Components Parts By Weight Dow DER 330, Dow Chemical l00.0 Silicon Carbide. I80 X. Simonds Abrasive Div.. The Wallace Murray Corp. 90.0 Coors METLX" Pellets 400.0 Trimelltic Anhydride, Amoco Chemical Company 500 It will be noted that this last example is not a twocomponent composition but rather only one. The composition of this example can be suitably packaged and applied at the point of use and then cured or hardened by heat. For example, after it is applied, it might be cured for two hours at about 250F. followed by an additional, say, 6-hour cure at 350F.
In the above examples it will be noted that the large particles and co-abrasive filler are in a ratio of on the order of 4 to I, while the particles (both large particles and co-abrasive filler) and matrix (resin, curing agent, etc.) are in a ratio on the order of 3 to I.
In certain situations. two parts of Stannous Octoate, supplied by the National Lead Company, could be added to the single component example to reduce the curing time to something on the order of five minutes at 300F.
The wearing composition may be applied or used on any one of a number of parts or surfaces. Good examples are feed chutes, buckets. hoppers, feed plates, pipe and elbows. side plates, diverter plates, discharge chutes and skirts, sand slinger, and the feed spout of grinding mills. It might also be used on trunnion liners, pump casing, return idlers, screens, dust collectors and cyclones and the like. The above are merely examples and it should be understood that other applications are important, such as the hard surfacing of classifier flights and shoes, the drums of cement trucks, fan blades, the surfacing of pan feeders, cobbler repulp circulators, the buckets and teeth of front end loaders, and so forth.
The large abrasive resistant particles have been stated as being high alumina ceramic particles, but a number of other particles could be used, such as boron nitride, tungsten carbide, silicon carbide, boron carbide and the like.
The large particles have been shown as generally round or spherical. But, in certain situations, chips might be used. Round particles may be used for a trowelable mix, but in certain applications, chips might be used. For example, if the composition is to be applied or cast, chips would not be objectionable and they might be less expensive. In certain situations, chips could be used in a trowelable mixture. This is particularly true in a casting system where different beads would be appropriate.
The examples both as to time and temperature given hereinabove are merely for purposes of description. The curing time is flexible and can be varied by modifying the formula somewhat to fit or suit any particular application. The same is true of curing temperature.
I claim:
1. A trowelable wearing composition for on-the-job application to a surface to provide a wearing surface having more resistance to wear caused by impact, abrasion, erosion or corrosion than NiHard iron, including a matrix composed of an uncured curable crosslinkable thermosetting resin, a curing agent for the resin and a thixotropic agent, large abrasion resistant ceramic particles on the order of one-sixteenth inch in their largest dimension, much smaller co-abrasion resistant filler particles on the order of 180 mesh size and of a hardness on the order of that of the material causing the wear dispersed in rather random fashion among the large particles when applied, the ceramic and filler particles being in a ratio on the order of 4 to l by weight, and the particles and matrix being in a ratio on the order of 3 to l by weight.
2. The composition of claim I further characterized in that the large abrasion resistant particles are metal coated alumina ceramic particles.
3. The composition of claim 1 further characterized in that the large ceramic particles are essentially spherical beads.
4. The composition of claim I further characterized in that the co-abrasion resistant filler is silicon carbide.
5. The composition of claim 1 further characterizied in that the thermosetting resin is an epoxy resin.
6. A curable resin composition for on-the-job application to a surface to provide a wearing surface having more resistance to wear than NiHard iron, a unitary system including a container of a certain amount of the uncured resin with large abrasion resistant ceramic particles on the order of one-sixteenth inch in their largest dimension and much smaller co-abrasion resistant filler particles on the order of I mesh size therethrough and of a hardness on the order of that of the material causing the wear, and a separate container with a proportionate amount of a curing agent and with large abrasion resistant ceramic particles on the order of one-sixteenth inch in their largest dimension and much smaller co-abrasion resistant filer particles on the order of I80 mesh size therethrough whereby the contents of both containers are capable of mixing readily by the existence of large and much smaller abrasive particles in each container, the ceramic and filler particles being in a ratio on the order of 4 to I by weight and the particles and resin plus curing agent being in a ratio on the order of 3 to l by weight when the contents of both containers are combined.
7 8 7. The composition of claim 6 further characterized in that the smaller co-abrasion resistant filler particles in that the large abrasion resistant ceramic particles are are Silicon carbide metal coated alumina ceramic particles.
8. The composition of claim 6 further characterized in that the large ceramic particles are spherical beads. 9. The composition of claim 6 further characterized 10. The composition of claim 6 further characterized in that the resin is an epoxy resin.
ii IR l

Claims (10)

1. A TROWELABLE WEARING COMPOSITION FOR ON-THE-JOB APPLICATION TO A SURFACE TO PROVIDE A WEARING SURFACE HAVING MORE RESISTANCE TO WEAR CAUSED BY IMPACT, ABRASION, EROSION OR CORROSION THAN NIHARD IRON, INCLUDING A MATRIX COMPOSED OF AN UNCURED CURABLE CROSSLINKABLE THERMOSETTING RESIN, A CURING AGENT FOR THE RESIN AND A THIXOTROPIC AGENT, LARGE ABRASION RESISTANT CERAMIC PARTICLES ON THE ORDER OF ONE-SIXTEENTH INCH IN THEIR LARGEST DIMENSION, MUCH SMALLER CO-ABRASION RESISTANT FILLER PARTICLES ON THE ORDER OF 180 MESH SIZE AND OF A HARDNESS ON THE ORDER OF THAT OF THE MATERIAL CAUSING THE WEAR DISPERSED IN RATHER RANDOM FASION AMONG THE LARGE PARTICLES WHEN APPLIED, THE CERAMIC AND FILLER PARTICLES BEING IN A RATIO OF THE ORDER OF 4 TO 1 BY WEIGHT, AND THE PARTICLES AND MATRIX BEING IN A RATIO ON THE ORDER OF 3 TO 1 BY WEIGHT.
2. The composition of claim 1 further characterized in that the large abrasion resistant particles are metal coated alumina ceramic particles.
3. The composition of claim 1 further characterized in that the large ceramic particles are essentially spherical beads.
4. The composition of claim 1 further characterized in that the co-abrasion resistant filler is silicon carbide.
5. The composition of claim 1 further characterizied in that the thermosetting resin is an epoxy resin.
6. A curable resin composition for on-the-job application to a surface to provide a wearing surface having more resistance to wear than NiHard iron, a unitary system including a container of a certain amount of the uncured resin with large abrasion resistant ceramic particles on the order of one-sixteenth inch in their largest dimension and much smaller co-abrasion resistant filler particles on the order of 180 mesh size therethrough and of a hardness on the order of that of the material causing the wear, and a separate container with a proportionate amount of a curing agent and with large abrasion resistant ceramic particles on the order of one-sixteenth inch in their largest dimension and much smaller co-abrasion resistant filer particles on the order of 180 mesh size therethrough whereby the contents of both containers are capable of mixing readily by the existence of large and much smaller abrasive particles in each container, the ceramic and filler particles being in a ratio on the order of 4 to 1 by weight and the particles and resin plus curing agent being in a ratio on the order of 3 to 1 by weight when the contents of both containers are combined.
7. The composition of claim 6 further characterized in that the large abrasion resistant ceramic particles are metal coated alumina ceramic particles.
8. The composition of claim 6 further characterized in that the large ceramic particles are spherical beads.
9. The composition of claim 6 further characterized in that the smaller co-abrasion resistant filler particles are silicon carbide.
10. The composition of claim 6 further characterized in that the resin is an epoxy resin.
US238183A 1972-03-27 1972-03-27 Composition to be applied to a surface to increase its wear resistance Expired - Lifetime US3876579A (en)

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Application Number Priority Date Filing Date Title
US238183A US3876579A (en) 1972-03-27 1972-03-27 Composition to be applied to a surface to increase its wear resistance
ZA731080A ZA731080B (en) 1972-03-27 1973-02-15 Method of applying a wearing surface
CA164,201A CA1010178A (en) 1972-03-27 1973-02-20 Method of applying a wearing surface
AU52440/73A AU475569B2 (en) 1972-03-27 1973-02-21 Method of applying a wearing surface
DE2311507A DE2311507C3 (en) 1972-03-27 1973-03-08 Method of applying a wear-resistant synthetic resin-bonded coating
SE7303825A SE404018B (en) 1972-03-27 1973-03-19 COATING PRODUCTS INTENDED TO BE APPLIED WITH SLEEVE IN PLACE AND CARE ON A SURFACE FOR THE OCCUPATION OF AN ABRASION-RESISTANT SURFACE WITH GREAT RESISTANCE TO SHOCK, WEARING, EROSION AND CORROSION CAUSED WEAR ...
BE129087A BE797127A (en) 1972-03-27 1973-03-21 PROCESS FOR FORMING A WEAR SURFACE
NL7304013.A NL163552C (en) 1972-03-27 1973-03-22 METHOD FOR COATING A SURFACE WITH A RESISTANCE TO RESISTANCE TO CORROSION, AND PROCESS FOR PREPARING MIXES SUITABLE FOR COATING.
ES413001A ES413001A1 (en) 1972-03-27 1973-03-26 Composition to be applied to a surface to increase its wear resistance
FR7310746A FR2178644A5 (en) 1972-03-27 1973-03-26
GB1464473A GB1431676A (en) 1972-03-27 1973-03-27 Applying an abrasive-resistant coating to a surface
BR732177A BR7302177D0 (en) 1972-03-27 1973-03-27 PROCESS TO INSTALL AN ABRASIVE-RESISTANT SYSTEM AND COMPOSITION FOR THE SAME USE
JP48034215A JPS527449B2 (en) 1972-03-27 1973-03-27
US06/182,031 USRE30691E (en) 1972-03-27 1980-08-28 Method of applying a wearing surface

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JP (1) JPS527449B2 (en)
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BR (1) BR7302177D0 (en)
CA (1) CA1010178A (en)
DE (1) DE2311507C3 (en)
ES (1) ES413001A1 (en)
FR (1) FR2178644A5 (en)
GB (1) GB1431676A (en)
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US3954694A (en) * 1975-02-03 1976-05-04 Rexnord, Inc. Wearing composition
US4042559A (en) * 1972-03-23 1977-08-16 The Carborundum Company Abrasion resistant coated abrasive pipe lining sheet
US4334970A (en) * 1976-11-05 1982-06-15 The Richardson Company Radiation curable solvent-free compositions recovery system
US4356037A (en) * 1980-05-12 1982-10-26 Novak Robert L Abrasion resistant coating
USRE33011E (en) * 1984-07-19 1989-08-08 Tennis racket frame made of metal oxide fibers and ceramic particles
US5753725A (en) * 1995-03-08 1998-05-19 Sumitomo Electric Industries, Ltd. Dry friction material and method of preparing the same
US6435810B1 (en) * 2000-10-20 2002-08-20 Delphi Technologies, Inc. Wear resistant fuel pump
US6436159B1 (en) * 1999-12-09 2002-08-20 Lilly Industries, Inc. Abrasion resistant coatings
US20050176321A1 (en) * 2003-10-14 2005-08-11 Crette Stephanie A. Fiber wear layer for flooring and other products
US20100087577A1 (en) * 2007-04-20 2010-04-08 Center for Abrasives and Refractories Research and Development C.A.R.R.D. GmbH Anti abrasion layer
US20100196696A1 (en) * 2007-07-11 2010-08-05 Technip France Method and apparatus for anchoring an elongate subsea structure to a termination and a filler material therefor
CN104031521A (en) * 2013-12-25 2014-09-10 广西宾阳县荣良新材料科技有限公司 Wood composite coating
CN106277933A (en) * 2016-07-29 2017-01-04 黄河水利委员会黄河水利科学研究院 A kind of high-toughness high-strength composite resin mortar
CN108654961A (en) * 2018-05-16 2018-10-16 安徽三环水泵有限责任公司 A kind of method for repairing and mending of flow passage component of slurry pump

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JPS5888480U (en) * 1981-12-09 1983-06-15 株式会社アサカ Broadcasting card changer
JPS58131174A (en) * 1982-01-29 1983-08-04 Sadashige Tokushu Gouban Kogyo Kk Production of decorative plate excellent in wear resistance
GB2120263B (en) * 1982-05-17 1985-07-31 Ciba Geigy Ag A process for curing acid-curable abrasive compositions
FI92419C (en) * 1990-11-19 1994-11-10 Valmet Paper Machinery Inc Roll coating method and roll coating
DE4226789A1 (en) * 1992-08-13 1994-02-17 Sigri Great Lakes Carbon Gmbh Fiber-reinforced plastic roller with outer, wear-resistant, filler-containing plastic layer
FR2708875B1 (en) * 1993-08-12 1995-09-29 Schmitt Ind Sarl Process for the treatment of furniture elements capable of withstanding significant constraints.
DE19625749C2 (en) * 1996-06-27 1998-12-17 Polywest Kunststofftechnik Process for producing a seamless printing form for rotary letterpress printing
DE102008006336B4 (en) * 2007-01-24 2017-12-14 Ilona Napp Process for the surface design of furnishing elements for a building and furnishing element for a building
CN109370385A (en) * 2018-11-05 2019-02-22 四川理工学院 A kind of wear-resisting scratch-resisting hurts coating and preparation method thereof
CN113372794A (en) * 2021-06-02 2021-09-10 清远市进田企业有限公司 Epoxy floor coating prepared from waste circuit board nonmetal powder and preparation method thereof

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Cited By (18)

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Publication number Priority date Publication date Assignee Title
US4042559A (en) * 1972-03-23 1977-08-16 The Carborundum Company Abrasion resistant coated abrasive pipe lining sheet
US3954694A (en) * 1975-02-03 1976-05-04 Rexnord, Inc. Wearing composition
US4334970A (en) * 1976-11-05 1982-06-15 The Richardson Company Radiation curable solvent-free compositions recovery system
US4356037A (en) * 1980-05-12 1982-10-26 Novak Robert L Abrasion resistant coating
USRE33011E (en) * 1984-07-19 1989-08-08 Tennis racket frame made of metal oxide fibers and ceramic particles
US5753725A (en) * 1995-03-08 1998-05-19 Sumitomo Electric Industries, Ltd. Dry friction material and method of preparing the same
US6641629B2 (en) * 1999-12-09 2003-11-04 Eugen Safta Abrasion resistant coatings
US6436159B1 (en) * 1999-12-09 2002-08-20 Lilly Industries, Inc. Abrasion resistant coatings
US6435810B1 (en) * 2000-10-20 2002-08-20 Delphi Technologies, Inc. Wear resistant fuel pump
US20050176321A1 (en) * 2003-10-14 2005-08-11 Crette Stephanie A. Fiber wear layer for flooring and other products
US20100087577A1 (en) * 2007-04-20 2010-04-08 Center for Abrasives and Refractories Research and Development C.A.R.R.D. GmbH Anti abrasion layer
US8410209B2 (en) 2007-04-20 2013-04-02 Center for Abrasives and Refractories Research and Development C.A.R.R.D. GmbH Anti abrasion layer
US8449977B1 (en) 2007-04-20 2013-05-28 Center for Abrasives and Refractories Research and Development C.A.R.R.D. GmbH Anti abrasion layer
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US9212767B2 (en) * 2007-07-11 2015-12-15 Technip France Method and apparatus for anchoring an elongate subsea structure to a termination and a filler material therefor
CN104031521A (en) * 2013-12-25 2014-09-10 广西宾阳县荣良新材料科技有限公司 Wood composite coating
CN106277933A (en) * 2016-07-29 2017-01-04 黄河水利委员会黄河水利科学研究院 A kind of high-toughness high-strength composite resin mortar
CN108654961A (en) * 2018-05-16 2018-10-16 安徽三环水泵有限责任公司 A kind of method for repairing and mending of flow passage component of slurry pump

Also Published As

Publication number Publication date
ZA731080B (en) 1974-12-24
ES413001A1 (en) 1976-05-16
NL7304013A (en) 1973-10-01
JPS498530A (en) 1974-01-25
BE797127A (en) 1973-07-16
BR7302177D0 (en) 1974-07-25
DE2311507C3 (en) 1980-02-28
AU5244073A (en) 1974-08-22
NL163552C (en) 1980-09-15
JPS527449B2 (en) 1977-03-02
GB1431676A (en) 1976-04-14
NL163552B (en) 1980-04-15
AU475569B2 (en) 1976-08-26
SE404018B (en) 1978-09-18
DE2311507B2 (en) 1979-06-28
DE2311507A1 (en) 1973-10-04
FR2178644A5 (en) 1973-11-09
CA1010178A (en) 1977-05-10

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