GB2436001A

GB2436001A - Abrasion resistant material

Info

Publication number: GB2436001A
Application number: GB0622522A
Authority: GB
Inventors: Alireza Kalantar-Harmozi
Original assignee: Individual
Current assignee: Individual
Priority date: 2005-11-11
Filing date: 2006-11-13
Publication date: 2007-09-12
Anticipated expiration: 2026-11-13
Also published as: GB0523011D0; GB0622522D0; GB2436001B

Abstract

An abrasion resistant material (1) is comprised of a flexible mesh-like structure (2) and a plurality of beads 3). The mesh-like structure is in the form of a sheet, of a predetermined thickness and can be supplied in roll form, and has an openwork, net-like appearance formed by the presence of a number of openings (4). The size of openings (4) corresponds to the size of beads (3), such that each opening is able to receive a bead (3) which is held in position in the mesh-like structure. In the depicted embodiment the beads are of a substantially spherical shape, although these may be ellipsoid or polyhedral. The beads may be formed of ceramic, metal, glass or polymeric material and the mesh may be formed of natural or synthetic fabric, polymer, metal or ceramic materials. Applications include a material for use as a centralizer in drilling operations, construction materials including heat and sound insulation material, anti-static material and therapy/massage applications.

Description

1 2436001 1 High abrasion resistant material 3 The present invention

relates to a high abrasion 4 resistant material.

6 Surfaces that regularly come into contact with abrasive 7 forces can deteriorate over time unless covered or coated 8 by an abrasion resistant material. Abrasion resistance 9 is important in several industries and abrasion resistant materials have many applications.

12 At present, abrasion resistant materials are used in 13 applications such as aircraft runways, car parks, factory 14 floors and shop floors. However, the materials that are currently used have several disadvantages which restrict 16 their effectiveness and ease of use. For example many 17 existing abrasion resistant materials are applied using a 18 spray or brush, before curing the material. This method 19 of application makes it difficult to control the thickness of the abrasion resistant material, leading to 21 undesirable inconsistent surface thickness. As a result 22 this may produce a surface with thin spots which are 23 liable to deteriorate over time.

2 Other existing abrasion resistant materials require the 3 use of putty which is difficult to apply. Again, this 4 can result in a surface of variable thickness. Moreover, abrasion resistant materials that require the application 6 of putty, are generally best applied by a skilled person 7 using specialist tools.

9 Often, abrasion resistant materials used on flooring and walls are provided in the form of tiles. However such 11 tiles are separated by seams which present several 12 problems. For example, the seams between tiles are often 13 the location of bacterial growth which is undesirable in 14 areas of food preparation, bars, food shops, and hospitals where strict hygiene is of utmost importance.

16 Furthermore, the seams between the tiles present 17 initiation areas for cracking or breaking, which presents 18 a safety and a hygiene hazard.

Therefore, it is an object of the present invention to 21 overcome at least some of the drawbacks associated with

22 the prior art.

24 A further object of the invention is to provide an abrasion resistant material which can be readily applied 26 to a number of different surfaces.

28 Further aims and objectives of the invention will become 29 apparent from meeting the following descriptions.

31 According to the present invention there is provided an 32 abrasion resistant material comprising a plurality of 33 beads supported in a flexible mesh-like structure, said 1 flexible mesh-like structure having a configuration which 2 provides a plurality of openings, each opening being 3 suitable for receiving a bead.

Preferably the flexible mesh like structure takes the 6 form of a sheet.

8 The beads are preferably of a substantially spherical 9 shape. The beads may be ellipsoid or a polyhedron of substantially spherical shape.

12 Most preferably at least part of the surface of the 13 plurality of beads projects above the flexible mesh-like 14 structure.

16 The beads may be made from a ceramic, glass, plastic, 17 polymer, ceramic or metal.

19 Optionally the beads may be translucent.

21 The flexible mesh-like structure may be made from a 22 fabric, polymeric material or ceramic.

24 The flexible mesh-like structure may alternatively be made from metal. In this event the metal mesh-like 26 structure may be earthed. Advantageously this provides 27 the material with anti-static properties.

29 The size of the beads is not limited. In a preferred embodiment the size of the beads ranges from 31 approximately 1 to approximately 20 mm.

1 The material according to this invention offers a means 2 for improving the heat and abrasion resistance of a 3 surface. Advantageously as the material is flexible it 4 can be manipulated to correspond to the shape of the surface.

7 The material may be fixed to the surface using adhesive 8 or a substance such as cementitious or polymeric grout, 9 cement or polymer which sets to fix the material in position. In a preferred embodiment the material is held 11 in place by adhesive, prior to being fixed in position 12 using grout. Optionally once the material is fixed in 13 position the mesh-like structure can be removed.

The present invention will now be described by way of 16 example only, with reference to the accompanying drawing 17 in which: 18 Figure 1 is a cross section of one embodiment of the 19 abrasion resistant material in accordance with the present invention, and 21 Figure 2 is a schematic view of the material viewed from 22 above.

23 Referring to Figures 1 and 2 the abrasion resistant 24 material is generally depicted at 1 and is comprised of a flexible mesh-like structure 2 and a plurality of beads 26 3. The mesh-like structure is in the form of a sheet, in 27 other words it is of a predetermined thickness and can be 28 supplied in roll form, and has an openwork, net-like 29 appearance formed by the presence of a number of openings 4. The size of openings 4 corresponds to the size of 31 beads 3, such that each opening is able to receive a bead 1 3 which is held in position in the mesh-like structure.

2 In the depicted embodiment the beads are of a 3 substantially spherical shape.

4 At least part of the surface of the beads 4 projects above the surface of the mesh-like structure 2. This may 6 be by a marginal amount and invisible to the naked eye, 7 provided the beads 3 are presented such that in use, when 8 fixed to a surface, the top, upper surface 5 of the bead 9 becomes the contact point on the floor for external objects, in other words the point at which an object 11 first contacts the floor. This is made possible by the 12 shape of the beads -which are substantially spherical.

13 Thus when an object falls or is placed on the material it 14 makes point contact with the uppermost surface of the bead as opposed to the polymer matrix which binds the 16 beads. This point contact with beads, which are 17 manufactured from a hard material, prevent and impede the 18 object from penetrating any further into the material.

19 This minimises friction, abrasion and damage.

In use, the material is applied to the surface being 21 covered with lower portion 6 of the material positioned 22 adjacent to, and on said surface, whilst upper portion 7 23 which consists of the upper surface of the beads 3 faces 24 upwards and acts as the contact point for any object coming into contact with the surface. However in an 26 alternative embodiment, described below, and where it may 27 be desirable to remove the mesh after application, the 28 material may be applied to the surface with upper portion 29 7 positioned to, and on said surface and lower portion 6 facing upwards to act as the contact point for any object 3]. contacting the surface. The material can be applied to 1 a variety of surfaces including floors, walls and runways 2 as well as the surfaces of industrial tools.

3 In the embodiment shown in Figure 1 it can be seen that a 4 substantial amount of the bead projects about the flexible mesh-like sheet. However this is not intended 6 to limit the amount of bead which projects above the 7 mesh-like sheet, in other words more or less of the bead 8 than that shown in Figure 1 may project. In addition, 9 whilst the embodiments show the beads to be touching this is not considered to be an essential feature of the 11 invention and embodiments where the beads are not in 12 direct contact with each other are intended to fall 13 within the scope of the invention herein.

14 Whilst in the depicted embodiment each opening 4 of the flexible mesh-like structure 2 receives one bead, in 16 alternative embodiments each opening 4 may receive more 17 than one bead 3. In addition in the depicted embodiment 18 each of the openings 4 receives a bead 3. However, in 19 alternative embodiments some of the openings 4 may be without beads, for example a bead may be located in every 21 second opening 4, leaving an opening 4 without a bead 3 22 therebetween.

23 The majority of each of the beads 3 may be located within 24 its respective opening 4. Alternatively the majority of each of the beads may project above the mesh-like 26 structure 2. The beads may be embedded or stuck into the 27 openings 4 or simply held in position due to the 28 respective size between the opening 4 and bead 3. The 29 beads can be attached to the mesh by different type of adhesives, the choice of adhesive being determined 31 depending on the application. For example where the 1 surface is subject to high temperatures a heat resistant 2 adhesive would be selected. Suitable adhesives include 3 hot-melt or heat reactive adhesives, polyvinyl acetates, 4 polyamides, polyamines, polyurethanes, polycaprolactams epoxys, polychloroprem, or polybutane for example.

6 In the depicted embodiment the beads are of a 7 substantially spherical shape. However any shape of 8 beads could be used and in particular embodiments using 9 beads of other geometric shapes such as squares and polyhedrons are envisaged. However in the preferred 1]. embodiment substantially spherical or ellipsoid beads are 12 used. The size of the beads can be selected depending on 13 the Application for the material. In addition the size 14 of the beads may be varied within the material -f or example two or more different sizes of beads can be used.

16 The beads may be manufactured from a ceramic, glass, 17 polymer, plastic or metal material. When provided for 18 use in a hospital environment for example the beads may 19 be manufactured from stainless steel. In the preferred embodiment of the present invention the beads are 21 manufactured from a material having a Mohs hardness of up 22 to 9. Advantageously where the beads are manufactured 23 from a ceramic or glass material they may be transparent 24 which is desirable for aesthetic reasons. The mesh-like structure may be manufactured from a polymer, plastic, 26 fabric, ceramic or metal. In the latter case the 27 material can be earthed which has been found to offer 28 superior anti-static effects. In this embodiment it is 29 also desirable to have the beads manufactured from a metal. This offers a distinct advantage over existing 31 methods used to render a surface anti-static. At present 32 it is common for channels to be cut into the surface 1 being treated into which earth wires can be inserted. It 2 will be appreciated that an advantage of the present 3 invention lies in the fact that the surface being covered 4 does not need to be cut or breached but can simply be S covered by the material of the present invention, and 6 earthed. The material is suitable for application in 7 high traffic walkways such as those found in shopping 8 stores and centres and airports to eliminate antistatic 9 charge shock from people and also has particular industrial application, for example in oil and gas 11 industries and chemical plants flooring where static can 12 cause danger of explosion.

13 The flexible mesh-like structure can be manufactured from 14 a variety of materials such as metal, plastic, or polymers. In particular the flexible mesh-like structure 16 may be manufactured from a polyolef in such as 17 polyethylene, polypropylene, polyamide, 18 polyvinyichioride, acrylic, polycarbonate, polyester or 19 Teflon.

The material described herein is used to cover a surface 21 to create a high abrasion abrasion resistant surface with 22 a pre- controlled thickness. The material also renders 23 the surface non-slip and provides good grip. The 24 material also has an improved capacity to high temperatures, in other words it also has desirable and 26 improved temperature resistance. This improved heat 27 resistance is particularly useful when the material is 28 used for example on aircraft runways, such as those on 29 war ships, where there is a large heat shock as well as abrasion resistance means and a requirement for good grip 31 on the surface. Additionally the improved heat 32 resistance advantageously renders the surface suitable 1 for steam washing which is often required in 2 environmental health regulations. This makes the 3 material particularly suitable for use on flooring in 4 food factories and other areas where there is a requirement for the floor to be anti-slip and abrasion 6 resistant as well as heat resistant.

7 An advantage of the present invention is that the 8 material can be applied at a pre-determined thickness, 9 which is consistent over the whole of the surface to be covered. This is an improvement over prior art materials 11 which are typically sprayed or painted on a surface and 12 which tend to require specialist tools or skills to 13 ensure a consistent amount is applied. In contrast the 14 material of the present invention is supplied in such a form that it can be applied with minimum training or 16 requirement for specialist tools at a pre-controlled and 17 consistent thickness.

18 A further advantage is that the material is flexible.

19 This is predominantly achieved by selection of appropriate materials and by the fact that the material 21 takes the form of a mesh or web. The material can 22 therefore be easily transported, used and sold. In 23 addition the inherent flexibility of the material means 24 that it can be moulded, shaped or manipulated to cover any shape of surface required.

26 The material of the present invention provides a means to 27 cover a large surface with a predetermined and consistent 28 thickness of heat/abrasion resistant material.

29 Traditional materials used to improve heat or abrasion resistant are provided in the form of pre-mixed 31 compositions in spray or paint form. When using these 1 existing materials it is difficult to apply a consistent 2 and constant thickness of material over a surface. In 3 contrast as the thickness of the material described in 4 the present application is pre-determined, constant and can be selected according to the use required, the 6 material can be easily and quickly applied to the 7 surface.

8 In use the material is placed over a surface to be 9 covered and then fixed in place using a grout, cement or polymer substance which sets to fix the material in 11 place. The material can be temporarily held in place by 12 a suitable adhesive prior to grouting if required.

13 In one embodiment and as an option the mesh-like sheet 14 structure 4 could be removed after the material has been fixed into position, leaving the particles in position 16 within the grout or cement substance. In other words the 17 mesh will be used as a carrier to hold the beads in a 18 regular shape until they are installed onto the surface 19 being treated. In a number of applications, the mesh does not play any further role after the beads have been 21 installed on the surface, although presence of the mesh 22 is important where an antistatic property is required.

23 Nevertheless it is envisaged that to eliminate extra work 24 the mesh will generally be left in position on the surface. However, if preferred, the mesh can be simply 26 and easily removed. Typically in use the material is 27 applied to a surface with the mesh-like sheet structure 28 facing towards the surface and the beads facing up.

29 However if the material in applied in a reversed orientation, in other words if, after applying adhesive 31 to the surface being covered, the material is applied 32 with the beads facing down towards said surface, and then 1 left for a sufficient period of time to allow the 2 adhesive to dry, the mesh can simply be pulled away and 3 separated from the beads, which will be stuck to the 4 adhesive. As the adhesion between the beads and the adhesive is stronger than adhesion between the beads and 6 the mesh-like sheet structure the mesh can be removed 7 leaving the beads in place.

9 The use of a material comprising a mesh-like sheet structure supporting a plurality of, for example metallic 11 or polymeric, beads on a surface is preferable to simply 12 covering or coating said surface with that metallic or 13 polymeric material for a number of reasons. For example 14 the configuration of the material of the present invention provides more friction and the present material 16 therefore tends to be less slippery than a simple 17 coating. Additionally, due to the nature and weight of 18 polymeric/metallic materials it is generally necessary to 19 supply these in tile form if they are being used for covering/coating surfaces. This has inherent 21 disadvantages. In the first instance, it may not be 22 aesthetically desirable to have a surface covered by 23 tiles with seams between each tile. Secondly the 24 presence of seams between tiles on a surface may present hygiene problems as it is common for dirt and bacteria to 26 collect in these seams. These problems are negated by 27 the material of the present invention. As the material 28 is flexible and of a mesh configuration it is 29 substantially lighter and can be provided in the form of a roll, similar to wallpaper. In addition when fixed in 31 position on a surface it appears as a seamless continuous 32 surface, providing aesthetic and hygienic advantages over 33 existing materials.

1 The material herein described has a variety of uses, 2 three of which are now described.

3 The material can be employed as a centraliser for use 4 with down-hole tools commonly used in the oil exploration industry.

6 In this example the material comprises a series of small 7 beads (approximately 1.25 cm) interspersed by larger 8 beads (approximately 2.5 cm) such that when the material 9 is arranged in a cylindrical fashion, with the beads forming the outer face of the cylinder, the larger beads 11 define channels. The material has a steel mesh embedded 12 with alumina beads and is applied to the outside of a 13 drill string using a cement, thus forming a channelled 14 centraliser. The material is grouted with a high temperature resistant epoxy vinyl ester. The channels in 16 the centraliser facilitate the flow of debris, drilling 17 mud, and drilling fluid.

18 In use the channelled centraliser is exposed to very high 19 temperatures (circa 250 00) and abrasive debris and drilling mud. However, the material of the present 21 invention is highly abrasion resistant and demonstrates 22 resistance to high temperatures and abrasive materials.

23 Furthermore, the material of the present invention is 24 flexible and can move in accordance with the movement of a drill string.

26 In a further example, the material is used for heat and 27 sound insulation. In this example, the beads are 28 polystyrene foam, but may be any suitable heat and sound 29 insulating material.

1 The Applicant envisages that the material may also have 2 therapeutic uses. For example the material may be 3 incorporated into or positioned on a seat or walked upon 4 to provide massage and therapeutic benefits.

Improvements and modifications may be incorporated herein 6 without deviating from the scope of the invention.

Claims

1 CLAIMS 3 1. An abrasion resistant material comprising a 4 plurality

of beads supported in a flexible mesh-like structure, said flexible mesh-like structure having 6 a configuration which provides a plurality of 7 openings, each opening being suitable for receiving 8 a bead.

2. An abrasion resistant material as claimed in Claim 1 11 where the flexible mesh like structure is in the 12 form of a sheet.

14 3. An abrasion resistant material as claimed in the preceding Claims where the beads are of a 16 substantially spherical shape.

18 4. An abrasion resistant material as claimed in the 19 preceding Claims where the beads are ellipsoid.

21 5. An abrasion resistant material as claimed in the 22 preceding Claims where the beads are polyhedrons of 23 substantially spherical shape.

6. An abrasion resistant material as claimed in the 26 preceding Claims where at least part of the surface 27 of the plurality of beads projects above the 28 flexible mesh-like structure.

7. An abrasion resistant material as claimed in the 31 preceding Claims where the beads are made from a 32 ceramic.

1 8. An abrasion resistant material as claimed in the 2 Claims 1-6 where the beads are made from glass.

4 9. An abrasion resistant material as claimed in Claims 1-6 where the beads are made from a polymeric 6 material.

8 10. An abrasion resistant material as claimed in Claims 9 1-6 where the beads are made from metal.

11 11. An abrasion resistant material as claimed in the 12 preceding Claims where the beads are translucent.

14 12. An abrasion resistant material as claimed in the preceding Claims where the flexible mesh-like 16 structure is made from a natural or synthetic 17 fabric.

19 13. An abrasion resistant material as claimed in Claims 1-12 where the flexible mesh-like structure is made 21 from a polymeric material.

23 14. An abrasion resistant material as claimed in Claims 24 1-12 where the flexible mesh-like structure is made from a ceramic.

27 15. An abrasion resistant material as claimed in Claims 28 1-12 where the flexible mesh-like structure is made 29 from a metal.

31 16. An abrasion resistant material as claimed in Claim 32 15 where the flexible mesh-like structure is 33 earthed.

2 17. An abrasion resistant material as claimed in the 3 preceding Claims where the size of the beads ranges 4 from approximately 1 to approximately 20 mm.

S

6 18. An abrasion resistant material as claimed in the 7 preceding Claims which can be fixed to a surface 8 using adhesive or a substance such as cementitious 9 or polymeric grout, cement or polymer.

11 19. An abrasion resistant material as claimed in the 12 preceding Claims where the flexible mesh-like 13 structure is adapted such that it can be removed 14 once the material is in position.