Anti-skid and wear-resistant light weight conveyor belt and preparation method thereof

Abstract

The present application relates to a kind of anti-skid wear-resistant light transmission belt and its preparation method, the transmission belt includes rubber layer, the working surface of rubber layer is equipped with PVC coating liquid layer, the raw material of PVC coating liquid includes 80-120 parts of PVC resin, 3-10 parts of ultra-high molecular weight polyethylene powder, 10-20 parts of reinforcing agent, 30-40 parts of plasticizer, 3-6 parts of stabilizer, 4-6 parts of active agent, 1-5 parts of antioxidant and 0-10 parts of functional auxiliary agent by mass fraction.The working surface of the rubber layer has microtexture, and the PVC coating liquid is coated on the microtexture.The transmission belt prepared by the present application, due to the introduction of UHMWPE and the synergistic effect of microtexture surface, compared with the prior art, shows significantly improved anti-skid performance under dry, wet, oil and other conditions, while having excellent wear resistance, effectively prolonging the service life of the transmission belt, reducing the operation and maintenance cost.

Description

Technical Field

[0001] This invention belongs to the technical field of conveyor belt manufacturing, and more specifically, relates to a non-slip and wear-resistant lightweight conveyor belt and its manufacturing method. Background Technology

[0002] Conveyor belts, as an indispensable core component of modern industrial production and logistics systems, are widely used in many fields such as mining, port logistics, food processing, tobacco manufacturing, printing and packaging, and even emerging industrial automation. Their core function is to efficiently and continuously transport materials of various forms, making them a key link in ensuring smooth production processes and improving operational efficiency.

[0003] However, with the rapid development of industrial technology and increasingly stringent production requirements, the inherent limitations of traditional conveyor belts in terms of anti-slip and wear resistance are becoming increasingly apparent when facing complex working conditions such as high and low temperatures, humidity, oil stains, and chemical corrosion, as well as high-load impacts and the pursuit of long lifespan and high reliability. For example, in inclined conveying or wet and slippery environments, materials are prone to slipping and rolling, affecting conveying efficiency and even causing safety accidents. Furthermore, in the conveying of highly abrasive materials, rapid wear of the belt surface directly leads to a shortened conveyor belt lifespan, increasing maintenance costs and downtime. These industry pain points place higher demands on the performance of conveyor belts.

[0004] Against this backdrop, optimizing the formulation of conveyor belts, introducing high-performance rubber, special polymers, functional additives, and even nanomaterials, and combining them with advanced surface treatment technologies, has become the main research and development direction for improving their anti-slip and wear-resistant properties, extending their service life, and expanding their application fields. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of existing rubber conveyor belts in terms of anti-slip performance (especially under harsh working conditions such as wet and oil) and wear resistance, and to provide an anti-slip and wear-resistant lightweight conveyor belt and its preparation method.

[0006] The objective of this invention can be achieved through the following technical solutions:

[0007] A non-slip and wear-resistant lightweight conveyor belt includes a rubber layer, the working surface of which is provided with a PVC coating layer. By weight, the raw materials of the PVC coating layer include the following components: 80-120 parts PVC resin, 3-10 parts ultra-high molecular weight polyethylene powder, 10-20 parts reinforcing agent, 30-40 parts plasticizer, 3-6 parts stabilizer, 4-6 parts activator, 1-5 parts antioxidant, and 0-10 parts functional additives.

[0008] The rubber layer is the main layer forming the conveyor belt, primarily comprising a rubber matrix. Preferably, the rubber matrix includes at least one of natural rubber, butadiene rubber, styrene-butadiene rubber, and nitrile rubber. Applying a PVC coating layer to the rubber layer can effectively improve the conveyor belt's wear resistance, pressure resistance, and aging resistance.

[0009] The working surface of the rubber layer refers to the side that directly contacts the material.

[0010] More preferably, the rubber matrix is ​​a composite of natural rubber and synthetic rubber.

[0011] Preferably, the weight-average molecular weight of the ultra-high molecular weight polyethylene is 3 million to 7 million g / mol, and the average particle size is 30 to 150 μm.

[0012] The main purpose of introducing ultra-high molecular weight polyethylene (UHMWPE) is to utilize its extremely low coefficient of friction and excellent wear resistance to form a dispersed wear-resistant and friction-reducing phase on the surface of the rubber layer, thereby reducing abrasive wear.

[0013] Preferably, the ultra-high molecular weight polyethylene is in the form of 5-10 parts by weight.

[0014] Preferably, the reinforcing agent is at least one selected from carbon black, silica, light calcium carbonate, kaolin, talc, nano-silica, and chopped carbon fibers. The reinforcing agent is used to improve the tensile strength, tear strength, hardness, and abrasion resistance of the conveyor belt, maintaining its mechanical properties.

[0015] Preferably, the reinforcing agent is carbon black or silica, wherein the carbon black is carbon black N220, carbon black N330, carbon black N234, carbon black N550 or carbon black N774.

[0016] Preferably, the plasticizer is dioctyl phthalate or epoxidized fatty acid methyl ester; the stabilizer is a calcium-zinc composite stabilizer; and the activator is at least one of zinc oxide and stearic acid.

[0017] Preferably, the antioxidant comprises at least one of N-isopropyl-N'-phenyl-p-phenylenediamine (4010NA), 2-thiol-benzimidazole (MB), hydroquinone dimethyl ether (RD), amines, and hindered phenolic antioxidants.

[0018] The addition of antioxidants can slow down the aging process, resist aging factors such as heat, oxygen, ozone, and flex fatigue, capture free radicals, decompose peroxides, or form a protective film, thereby maintaining the mechanical properties of the conveyor belt in long-term use and indirectly ensuring the durability of its anti-slip and wear-resistant properties.

[0019] Preferably, the antioxidant is present in 1.5-3 parts by weight.

[0020] Preferably, the functional additives include at least one of antistatic agents, flame retardants, friction reducers, silane coupling agents, UV stabilizers, and antislip agents.

[0021] Specifically, the conveyor belt further includes a core layer, and the rubber layer is disposed on the surface of the core layer.

[0022] In this technical solution, the core layer, as the skeleton of the conveyor belt, is the main body that bears the load, providing sufficient longitudinal tensile strength and load-bearing capacity, and thus determining the tensile strength and stiffness of the conveyor belt. The main function of the rubber layer is to protect the core layer from material impact, abrasion, and environmental erosion, extending its service life.

[0023] The material of the core layer includes at least one of cotton canvas, nylon canvas, polyester canvas, aramid canvas, or steel wire rope.

[0024] The working surface of the rubber layer has a microstructure, and the PVC coating is applied to the microstructure.

[0025] Preferably, the microtexture is an array of tiny units with specific geometry, size, and arrangement.

[0026] Specifically, the geometric shape can be a circular pit array, a square convex dot array, a V-shaped or U-shaped microgroove network; the unit is a pit, convex dot, groove, column or a combination thereof; the depth of the microtexture is 10-200μm, preferably 30-100μm; the unit spacing is 50-300μm; the arrangement is a regular arrangement or a biomimetic pattern arrangement.

[0027] Specifically, the microtexture settings mainly serve the following functions: ① Under wet and slippery conditions, they act as channels for water / oil storage and drainage / oil discharge, disrupting continuous water / oil films, increasing the actual contact area, and providing a "wiper effect." ② They accommodate abrasive debris, reducing the plowing effect of abrasive particles on the contact surface. ③ They increase surface roughness and mechanical engagement points, improving macroscopic friction. ④ They protect UHMWPE particles and PVC resin, regulating wear behavior.

[0028] Specifically, the microtexture, in conjunction with UHMWPE in the formulation, modulates wear behavior primarily through the following ways: In the initial stages of wear, UHMWPE particles act as a "sacrificial phase," and their low-friction properties reduce adhesive wear. As wear progresses, some UHMWPE may form a thin transfer film at the recesses of the texture or on the matrix surface, further reducing the coefficient of friction and protecting the matrix material. The microtexture provides favorable geometric space and conditions for these processes.

[0029] Specifically, the core layer is combined with the rubber layer through a calendering process to form a conveyor belt.

[0030] Preferably, a buffer layer is provided between the rubber layer and the core layer.

[0031] The buffer layer is used to absorb impact energy, protect the belt core, and enhance the adhesion between the rubber layer and the belt core.

[0032] More preferably, the core layer comprises at least two layers, and an isolation layer is provided between adjacent core layers.

[0033] The main function of the isolation layer is to provide good adhesion to adjacent core layers and ensure the bonding strength between the layers.

[0034] A method for preparing a conveyor belt as described above includes the following steps:

[0035] S1. Etch the microstructure on the working surface of the rubber layer of the conveyor belt and clean the working surface.

[0036] S2. Add the raw materials for the PVC coating liquid layer to a high-speed mixer and mix evenly to obtain the PVC coating liquid;

[0037] S3. Apply PVC coating liquid to the working surface of the rubber layer, then place the coated conveyor belt into the drying tunnel, dry and cure, and after cooling, obtain a non-slip and wear-resistant conveyor belt.

[0038] Further, the specific operation steps of step S1 are as follows: the conveyor belt with the rubber layer is placed in a mold with a specific micro-texture cavity, and a high temperature and high pressure reaction is carried out to make the working surface of the rubber layer replicate the preset micro-texture.

[0039] Specifically, the working surface of the mold is pre-fabricated with a cavity structure that is the reverse of the required microstructure using precision machining technology.

[0040] Specifically, the precision machining technology can be laser etching, electroforming, or LIGA technology.

[0041] Furthermore, the precision machining technology is femtosecond laser etching technology, with a pulse width <200 fs, a wavelength of 1000-1300 nm, and a power density of 4-6 × 10⁻⁶. 13 W / cm 2 The pulse frequency is 0.5-1.5MHz, and the scanning speed is 400-600mm / s.

[0042] Furthermore, in step S1, the ultra-high molecular weight polyethylene powder is added in batches to promote its uniform dispersion in the PVC resin.

[0043] Further, in step S2, the high-speed mixer rotates at 8000-12000 rpm for 10-15 minutes. Subsequently, a solvent is added to adjust the viscosity of the coating solution to adjust the PVC coating solution to 30-50 Pa·s.

[0044] Specifically, the solvent used to adjust the viscosity of the coating liquid is toluene, xylene, or ethyl acetate.

[0045] In step S3, the coating method is scraping, rolling, or spraying; the coating thickness is 0.5-2mm.

[0046] Preferably, in step S3, the drying and curing temperature is 80-120℃, and the drying time is 10-20 minutes.

[0047] The beneficial effects of this invention are:

[0048] (1) Microtexture can effectively disrupt the water / oil film at the interface and increase the mechanical meshing effect. UHMWPE itself has a low coefficient of friction, but when combined with microtexture, it exhibits more stable friction behavior at the contact point, which can effectively reduce slippage and improve conveying efficiency and safety.

[0049] (2) UHMWPE is dispersed in PVC resin in the form of micro powder, which can significantly resist abrasive wear and fatigue wear. The presence of micro-texture may reduce secondary wear by accommodating abrasive debris. On the other hand, the raised parts of the textured unit bear the wear first, which can protect the matrix and thus significantly extend the service life of the conveyor belt.

[0050] (3) By optimizing the types and amounts of each component in the formula, especially the content and particle size of UHMWPE, and by using reasonable processing technology, this invention can achieve a significant improvement in anti-slip and wear-resistant properties while maintaining the basic physical and mechanical properties of rubber materials such as elasticity, tensile strength, and tear strength, thus meeting the actual usage requirements of conveyor belts. Detailed Implementation

[0051] To further illustrate the technical means and effects of the present invention in achieving its intended purpose, the following detailed description of the specific implementation methods, structures, features, and effects of the present invention, in conjunction with embodiments, is provided below.

[0052] Example 1

[0053] A non-slip and wear-resistant lightweight conveyor belt includes a rubber layer, the working surface of which is provided with a PVC coating layer. The PVC coating layer comprises the following components and parts by weight:

[0054] Raw material name Specification / model Weight parts PVC resin SG-5 100 UHMWPE powder about 5.0 x 10 6 g / mol, average particle size 80 μm 5 Carbon black N330 Average particle size 32 nm 15 Zinc oxide Purity ≥ 99.7% 2 Stearic acid Type 1801 2 Antioxidant RD / 1 Antioxidant 4010NA / 1 DOP plasticizer / 30 Epoxy soybean oil / 5 Calcium-zinc composite stabilizer / 4 Silane coupling agent KH-550 2

[0055] The non-slip and wear-resistant lightweight conveyor belt of this embodiment includes a core layer and a rubber layer. The rubber layer is disposed on the surface of the core layer, and the working surface of the rubber layer is a layer that directly contacts the material. The PVC coating layer is disposed on the working surface of the rubber layer, and the working surface of the rubber layer has a preset microstructure.

[0056] The core layer is made of EP200 polyester canvas, and the core layer consists of two layers.

[0057] The manufacturing process of the transmission belt in this embodiment is as follows:

[0058] S1. Cut the conveyor belt blank into appropriate sizes and place it in the mold of the flat vulcanizing agent. The surface of the upper template cavity of the mold is pre-prepared with a micro-texture by laser etching process, specifically a regular array of circular pits with a diameter of 100μm, a depth of 50μm, and a center-to-center spacing of 150μm. Set the vulcanization temperature to 150±2℃, the pressure to 10MPa, and the vulcanization time to 25 minutes, and perform molding vulcanization to etch the micro-texture on the working surface of the rubber layer, and clean the working surface.

[0059] S2 and UHMWPE powders were pre-treated with coupling agent KH-550 for surface modification. Then, PVC resin and plasticizer were added to a high-speed mixer and mixed at 80°C for 10 minutes until the resin was fully swollen. Other raw materials were then added and stirred at 8000-12000 rpm for 15 minutes to ensure thorough mixing. Ethyl acetate solvent was then slowly added and mixed thoroughly. The viscosity of the coating solution was adjusted to 30-50 Pa·s, and stirring was continued for 5 minutes to obtain the PVC coating solution.

[0060] S3. Apply the PVC coating liquid to the working surface of the rubber layer using a roller coating method. The coating thickness is 0.5-2mm. Then, place the coated conveyor belt into the drying tunnel and dry and cure it at a temperature of 100±0.5℃ for 15 minutes to allow the solvent in the PVC coating liquid to completely evaporate. After cooling, a non-slip and wear-resistant conveyor belt is obtained.

[0061] Example 2

[0062] The difference between this embodiment and Embodiment 1 is that in this embodiment, carbon black N330 is replaced with 6 parts of nano-silica and 4 parts of chopped carbon fiber. The weight-average molecular weight of the UHMWPE powder is approximately 7.0 × 10⁻⁶. 6 g / mol, average particle size 30 μm.

[0063] Example 3

[0064] The difference between this embodiment and Embodiment 2 is that the weight-average molecular weight of the UHMWPE powder is approximately 3.0 × 10⁻⁶. 6 g / mol, average particle size 120 μm.

[0065] Example 4

[0066] The difference between this embodiment and embodiment 1 is that, after step S3, the conveyor belt is subjected to plasma treatment with a power of 150W for 5 minutes.

[0067] Comparative Example 1

[0068] The difference between this comparative example and Example 1 is that the PVC coating liquid in this comparative example does not contain UHMWPE powder, and the weight of carbon black N330 is 20 parts. All other components, preparation steps, and parameters are the same.

[0069] Comparative Example 2

[0070] The difference between this comparative example and Example 1 is that this comparative example lacks step S1, that is, the rubber layer has no microstructure, while the other components, preparation steps and parameters are the same.

[0071] The samples obtained in Examples 1-4 and Comparative Examples 1-2 were left to stand for 24 hours at a temperature of 23±2℃ and a relative humidity of 50±5%RH, and then the following performance tests were performed.

[0072] (1) Anti-slip performance test

[0073] Contact materials: Clean and dry SUS304 standard steel plate; water-lubricated steel plate (surface covered with a water film of approximately 0.1 mm); oil-lubricated steel plate (surface covered with an ISO VG32 mineral oil film).

[0074] Normal load: 5N ± 0.05N;

[0075] Test speed (pre-stretched and then stationary, then pulled at a constant speed): 100±10mm / min

[0076] Referring to GB / T10006-2021 (Method for Determination of Coefficient of Friction of Plastic Films and Sheets), the MXD-02 friction coefficient meter was used to test the maximum friction force of the contact auxiliary material when it initially slides on the sample conveyor belt, and the static friction coefficient was calculated.

[0077] (2) Wear resistance test

[0078] Load: 10.0±0.2N;

[0079] Abrasive: No. 60 alumina sandpaper; the abrasiveness of the sandpaper was calibrated with standard styrene-butadiene rubber before the test.

[0080] Wear stroke: 40m;

[0081] Grinding drum speed: 40±1 rpm;

[0082] Referring to ISO 4649:2017 (Determination of abrasion resistance of rubber or thermoplastic elastomers using a rotating cylindrical drum apparatus), the volume loss (mm) of the sample was measured using a DIN abrasion tester. 3 ).

[0083] The test results are shown in Table 1.

[0084] Table 1

[0085]

[0086] As shown in Table 1, the samples in Examples 1-4, which use a microtextured surface and UHMWPE-reinforced rubber composite formulation, exhibit superior and more stable frictional properties compared to Comparative Examples 1-2. In the standard DIN abrasion test, the abrasion volume loss of the samples in Examples 1-4 is significantly lower than that of Comparative Examples 1-2, indicating that they have a better ability to resist abrasive wear. Comparative analysis clearly reveals a positive synergistic enhancement effect between the introduction of UHMWPE and the design of the surface microtexture.

[0087] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention in any way. Although the present invention has been disclosed above with reference to preferred embodiments, it is not intended to limit the present invention. Any person skilled in the art can make some modifications or alterations to the above-disclosed technical content to create equivalent embodiments without departing from the scope of the present invention. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention without departing from the scope of the present invention shall still fall within the scope of the present invention.

Claims

1. A method for preparing a non-slip and wear-resistant lightweight conveyor belt, characterized in that, The conveyor belt includes a rubber layer, and the working surface of the rubber layer is provided with a PVC coating layer. By weight, the raw materials of the PVC coating layer include the following components: 80-120 parts PVC resin, 3-10 parts ultra-high molecular weight polyethylene powder, 10-20 parts reinforcing agent, 30-40 parts plasticizer, 3-6 parts stabilizer, 4-6 parts activator, 1-5 parts antioxidant and 0-10 parts functional additives. The ultra-high molecular weight polyethylene has a weight-average molecular weight of 3 million to 7 million g / mol and an average particle size of 30 to 150 µm. The working surface of the rubber layer has a microtexture, and the PVC coating liquid is applied to the microtexture; The microtexture is an array of tiny units with specific geometric shapes, sizes, and arrangements; The unit is a pit, a protrusion, a groove, a column, or a combination thereof; the depth of the microtexture is 10-200µm; the unit spacing is 50-300µm; the arrangement is a regular arrangement or a biomimetic pattern arrangement. The preparation method includes the following steps: S1. Etch the microstructure on the working surface of the rubber layer of the conveyor belt and clean the working surface. S2. Add the raw materials for the PVC coating liquid layer to a high-speed mixer and mix evenly to obtain the PVC coating liquid; S3. Apply PVC coating liquid to the working surface of the rubber layer, then place the coated conveyor belt into the drying tunnel, dry and cure, and after cooling, obtain a non-slip and wear-resistant conveyor belt. S4. The conveyor belt is treated with plasma; In step S2, the speed of the high-speed mixer is 8000-12000 rpm, and the stirring time is 10-15 minutes. Then, a solvent is added to adjust the viscosity of the coating liquid to adjust the PVC coating liquid to 30-50 Pa·s. In step S3, the drying and curing temperature is 80-120℃, and the drying time is 10-20 minutes.

2. The method for preparing a non-slip and wear-resistant lightweight conveyor belt according to claim 1, characterized in that, The reinforcing agent is at least one of carbon black, silica, light calcium carbonate, clay, talc, and chopped carbon fiber.

3. The method for preparing a non-slip and wear-resistant lightweight conveyor belt according to claim 1, characterized in that, The plasticizer is dioctyl phthalate or epoxidized fatty acid methyl ester; the stabilizer is a calcium-zinc composite stabilizer; and the activator is at least one of zinc oxide and stearic acid.

4. The method for preparing a non-slip and wear-resistant lightweight conveyor belt according to claim 1, characterized in that, The antioxidant includes at least one of N-isopropyl-N'-phenyl-p-phenylenediamine, 2-thiol-benzimidazole, hydroquinone dimethyl ether, and hindered phenolic antioxidants. The functional additives include at least one of the following: antistatic agents, flame retardants, friction reducers, silane coupling agents, UV stabilizers, and antislip agents.

5. The method for preparing a non-slip and wear-resistant lightweight conveyor belt according to claim 1, characterized in that, The depth of the microtexture is 30-100µm.

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