Insertion element, roller system and method for producing insertion element

Abstract

The invention relates to an insertion element (1), in particular for guiding a rope or a cable, in particular for guiding a rope or a cable of a cableway installation. The interposer element (1) comprises: a main layer (2); and a secondary layer (3) arranged in and / or on the primary layer (2). The insert element (1) has a first insert element side (4), which is designed to be in contact with an element (8) to be guided, in particular a rope or cable, in a guiding direction, in particular in a circumferential direction, and a second insert element side (6) opposite the first insert element side (4). The primary layer (2) and the secondary layer (3) differ in at least one material property. The insertion element (1) has a substantially constant cross-section in the guiding direction. The insert element (1) extends in a cross-section in a radial direction (R) and in a width direction (B), which are each orthogonal to the guide direction and orthogonal to each other. The invention further relates to a roller system (100) and to a method for producing an insert element.

Description

[0001] This invention relates to an insertion element, particularly an insertion element for guiding ropes or cables, especially for guiding ropes or cables in cableway facilities; to a roller system, particularly a roller system for guiding ropes or cables, especially for guiding ropes or cables in cableway facilities; and to a method for manufacturing the insertion element, particularly a method for manufacturing the insertion element for guiding ropes or cables, especially a method for manufacturing the insertion element for guiding ropes or cables in cableway facilities.

[0002] Insert elements or insert liners are used to guide, deflect, and drive circulating ropes, or anywhere on a cableway or track to guide a load. Such insert elements can take the form of closed or open loops, segments, or ropes (longitudinal profiles). Typically, one or more profiles (i.e., geometries) can be combined on the side facing the rope or web / track guide, with their geometry corresponding to the rope, web, or track.

[0003] Known insert elements typically comprise an outer layer that contacts the rope to be guided and a reinforcing inner layer that ensures the insert element sits on a rim or similar object. Additionally, insert elements are known to be able to be secured to rollers or similar objects via clamping mechanisms on their sides. Particularly for this type of insert element, no reinforcing internal insertion is required, thus the insert element consists of only a single outer layer.

[0004] It is known that the outer and inner layers of an insert element are typically designed to have a long service life. This ensures that the insert element has a sufficient service life.

[0005] However, these designs, intended for long service life, present problems because they make it difficult or impossible to achieve other desired characteristics of the insert element. In particular, as the applications of such insert elements expand, such as in urban cable car systems, the requirements for insert elements are increasing, including vibration resistance, noise reduction, high conductivity, vibration damping, and / or braking characteristics.

[0006] Therefore, the object of the present invention is to provide an insert element that can ensure a wider range of uses.

[0007] The above objective is achieved by an insert element having the features of claim 1, a roller system having the features of claim 29, and a method for manufacturing the insert element having the features of claim 30.

[0008] According to one aspect of the invention, an insertion element is provided, particularly for guiding ropes or cables, especially for guiding ropes or cables in a cableway system. The insertion element may include a main layer and a secondary layer disposed in and / or on the main layer. The insertion element may have a first insertion element side and a second insertion element side opposite to the first insertion element side, the first insertion element side being designed to contact the element to be guided, particularly the rope or cable, in the guiding direction, particularly the circumferential direction. The main layer and the secondary layer may differ in at least one material property. The insertion element may have a substantially constant cross-section along the guiding direction. The insertion element may extend in cross-sections in both the radial and width directions, wherein the radial and width directions are each orthogonal to the guiding direction.

[0009] In cable loops (e.g., insert elements) known in the prior art, a trade-off is made between the dynamic and mechanical properties of the material. In contrast, according to one aspect of the invention, the insert element has different layers (e.g., material layers) to improve both abrasion resistance and dynamic properties. On the one hand, this results in a longer service life for the insert element; on the other hand, it opens up new areas of application for high-stress applications. In other words, a multi-layered composite system can be provided as an insert liner (i.e., insert element) for guiding, deflecting, and driving circulating ropes. The insert element can be a closed or open loop. Furthermore, the insert element can also be designed as an insert rope. The insert element can be fixed in an insert on a wheel or rim. Furthermore, the insert element can be positioned, particularly clamped, between two flanged wheels. The insert element can be a separate component and designed to be fixed to a roller. For example, the roller can be rotatably held on a structure such as a support. For example, the roller can be rotatably mounted on the structure via a sliding bearing or roller bearing. A rope or cable can be placed on the insert element and supported and / or guided by it. The guiding direction (e.g., the rope guiding direction) can specify the direction of extension of the rope to be guided. The insert element can also be designed to support the rope and prevent lateral displacement transverse to the guiding direction. The insert element can have a lower strength than the rollers that secure it. In other words, the insert element can be formed of an elastic material that at least partially surrounds the rope to be guided. To improve guiding characteristics, the insert element can at least partially conform to the shape of the rope to be guided. Furthermore, the insert element can be designed as a strand-like element that can be attached to a component to prevent direct contact between the rope or cable and the component. It is also conceivable that the insert element can be designed as an insert rope that can be placed or wound around a guiding component. These guiding components can, for example, be wheels or discs for driving or deflecting the rope. In this case, the liner is typically connected to the wheel or disc by a clamping or threaded connection. Furthermore, the insert element can not only be designed to guide ropes or cables, but also to contact a track or the like for guidance on a track. For example, the insert element can serve as a wheel rim that can be attached to the wheel body. The primary and secondary layers can each be volumetric layers extending in all three spatial directions. The secondary layer may be wholly or partially disposed within the primary layer. Furthermore, the secondary layer may be disposed on the surface of the primary layer. The insertion element formed by the primary and secondary layers may have a first insertion element side and a second insertion element side. Within the meaning of this invention, a layer may be a planar layer having a defined and definite extent. In particular, particles, composite materials, or the like added to the casting compound, for example, during the casting of the insertion element, cannot be considered layers. Such additions, in particular, form a random, indeterminate arrangement and are not layers in the sense of this invention. The first insertion element side may be oriented substantially parallel to the second insertion element side. The first insertion element side may be the side of the insertion element that contacts the rope or track during use.The second insert element side may contact the rim, wheel hub, or other object on which the insert element is disposed. In terms of surface area, the first and second insert element sides may be the largest sides of the insert element. The insert element side may be defined by the edge of the insert element. The guiding direction may be the direction in which the rope, cable, or track passes through the insert element during use. The primary and secondary layers may be layers of different materials. For example, this can be characterized by the two layers having at least one different material property. Therefore, the insert element may be provided with at least two layers, wherein these layers are different. Thus, a combination of characteristics of the insert element to be implemented can be provided to obtain a wider range of insert elements for overall use. Therefore, the insert element can be configured as a multi-layered insert element with a hybrid structure, wherein the primary and secondary layers may be disposed in different positions and combinations within the cross-section of the insert element. The cross-section of the insert element may be a cross-section of the insert element along the primary extension direction. Furthermore, the cross-section may extend along the guiding direction of the insert element. In the case where the insert element is designed as a ring element, the guiding direction may extend in the circumferential direction. In other words, the rope guided by the insert element may be guided along or tangentially through the insert element. A constant cross-section can mean that the spatial extent of the cross-section varies by no more than 10% along the guiding direction or the direction in which the insert extends. In other words, the distribution or arrangement of the primary and secondary layers in the cross-section of the insert can also remain constant. If the insert is cut at different locations along the guiding direction, these layers can always be arranged substantially constant (i.e., identical). In other words, this does not imply a random distribution of layers in the cross-section. Observed in the cross-section of the insert (i.e., a two-dimensional view of the cross-section), one extending direction can be defined as the width direction, and another extending direction at a 90° angle to the width direction can be defined as the radial direction. In other words, the width direction can extend along the first insert side and / or along the second insert side. The radial or vertical direction can be a direction pointing away from the first insert side. By using different layers in the composite material of the insert, undesirable trade-offs in material development can be avoided, and inserts with a variety of properties can be provided by optimizing the position and size of the individual layers. For example, inserts with dynamically optimized inner layers and mechanically and / or wear-resistant optimized outer layers can be created. Furthermore, conductivity adjustments of the outer and / or inner layers can be implemented (e.g., for signal transmission or potential equalization). Sound suppression or vibration suppression can be implemented in the outer and / or inner layers. Additionally or alternatively, the friction and braking characteristics of the insert element can be optimized. Furthermore, the weather resistance of the outer layer can be optimized. Additionally, options can be provided for refurbishing the insert element and / or using recycled raw materials to improve its recyclability.

[0010] Preferably, the primary layer and secondary layer are each designed as an elastomer layer or a polymer layer. By using an elastomer, the dynamic and abrasion resistance properties of the insert element can be optimally tuned. For example, a mixture of different polymers can be provided for tuning. Furthermore, at least one filler can be added to the polymer to adjust certain properties. For example, carbon black and / or silica can be used as fillers. In addition to the internationally valid ASTM classification of carbon black, carbon black can also be classified as highly reactive, reactive, semi-reactive, and low-reactive carbon black. High-reactive carbon black can have a large surface area, while low-reactive carbon black can have a small surface area. By using carbon black as a filler, the conductivity of the layer can be tuned. Furthermore, using highly reactive carbon black can improve abrasion resistance. In contrast, using low-reactive carbon black can improve dynamic behavior (heat generation) compared to highly reactive carbon black. Heat generation can be determined according to Goodrich tests (DIN 53533, ASTM D 623, ISO 4666 / 3, 4666 / 4, BS 903 part A50, or JISK 6265). Heat generation can be broadly understood as how much heat is generated in a material under dynamic loads, such as through flexure. Excessive heat generation within the material can be avoided through favorable dynamic properties. This can counteract the thermal failure of the material. Furthermore, polymers or elastomers, for example, have improved vibration and sound suppression compared to Becorit. Additionally, polymers or elastomers have a low coefficient of friction. Preferably, the secondary layer is an abrasion-resistant layer. The abrasion-resistant layer can have special mechanical properties to minimize wear. For example, the secondary layer can be disposed on the first insertion element side and is therefore designed to be in direct contact with ropes, cables, or rails, and in such contact, wear on the secondary layer is reduced due to its abrasion resistance. In contrast, the primary layer can be designed for other properties to provide an overall advantageous insertion element. Preferably, the secondary layer is at least partially disposed on the first insertion element side. For example, the secondary layer can be only partially (i.e., only partially) disposed in the cross-section of the insertion element. This can produce an insertion element where both the primary and secondary layers are present on the surface of the first insertion element side. The secondary layer can, for example, be designed to have particularly low abrasion when in contact with the rope, cable, or track to be guided. The primary layer can, for example, have vibration-damping, conductive, and sound-absorbing material properties to ensure properties of the insert element other than abrasion resistance. In this way, an insert element that can be used in many application areas can be provided.

[0011] Preferably, at least one material property includes abrasion resistance, heat generation, electrical conductivity, sound suppression, vibration suppression, coefficient of friction, weather resistance, and / or thermal conductivity. Abrasion resistance can be characterized by low wear during insert element operation. Furthermore, abrasion resistance can be achieved through high strength and / or high resistance to tear propagation. Therefore, the insert element can be particularly durable and maintain long-term use. Heat generation or heat generation testing can be determined according to Goodrich tests (DIN 53533, ASTM D 623, ISO 4666 / 3, 4666 / 4, BS 903 part A50, or JIS K 6265). Heat generation can be broadly understood as how much heat is generated in the material under dynamic loads, such as through flexure. If the resistivity is ≤10... 4 If Ohm x cm, then the inserted element can be described as conductive. 10 4 Ohm x cm < resistivity ≤ 10 6 An insert element with an impedance of ohm x cm can be called an antistatic insert element. Resistivity > 10 6 Ohm x cm and ≤10 8 An insertion element with an ohm x cm value can be called an electrically neutral insertion element. Resistivity > 10 8 An insert element with an Ω x cm diameter can be called an insulating insert element. This means that the insert element can be adapted to specific application areas (e.g., signal transmission, potential equalization, etc.). For example, an insert element with at least two distinct layers can be used to make the outer layer (e.g., the primary layer) conductive or insulating. The inner layer (e.g., the secondary layer) can then determine, for example, the dynamic properties of the insert element. For example, current can be transmitted via a cord through the insert element to a flange disk in contact with the insert element. Furthermore, by providing only a partially conductive layer (e.g., the primary or secondary layer), the insert element can be provided as a multi-component system that provides mechanically optimized and conductive materials without requiring a conductive overall system. Conductivity can be achieved, for example, by adding carbon black to one of the layers.

[0012] Especially for cableway facilities in urban applications, sound insulation and / or vibration suppression may be required. This allows for a reduction in noise emissions. In the prior art, this problem is currently addressed by using materials optimized for noise emission characteristics in the insert element, but this adversely affects the expected lifespan of the insert element. The insert element according to this embodiment provides a multi-layered composite system that reduces the expected drawbacks of the noise-reducing layer on the overall system (i.e., the entire insert element) because the noise-reducing layer is only partially or locally used in the insert element, and layers with other properties can also be provided, such as dynamically optimized layers and / or layers that can provide increased abrasion resistance. The noise-reducing characteristics can be optimized and varied by changing the layer thickness in the radial direction. This allows the insert element to be adapted to the appropriate location and application. Dynamic optimization can mean providing the lowest possible heat generation while ensuring abrasion resistance.

[0013] according to Section A.2.1 of 12385-8, "Coefficient of Friction," defines the coefficient of friction as satisfying the requirements of the insert element under defined operating conditions (e.g., dry or lubricated conditions). Since only one outer layer affects the coefficient of friction of the insert element, the entire system can be optimized by adding another layer that is not disposed on the surface of the insert element. For example, a primary layer can have the desired coefficient of friction and be disposed on the first insert element side, while a secondary layer can ensure the necessary dynamic resistance of the insert element. In this way, an overall system can be achieved that satisfies the coefficient of friction requirement while also being optimized in other characteristics (e.g., dynamic characteristics or vibration damping characteristics). Dynamic resistance characterizes durability under dynamic loads.

[0014] Furthermore, the layers (primary or secondary layers) disposed on the side of the first insert element may include at least one material property, such as weather resistance. Weather resistance also focuses on the environmentally oriented (i.e., external world) layers of the insert element. Thus, for example, if the primary layer is disposed on the side of the first insert element, the primary layer can be designed to be particularly weather-resistant. In contrast, secondary layers disposed more inward in the radial or vertical direction can ensure other properties of the insert element, such as dynamic drag. In terms of climate change and expansion of application areas, the insert element can therefore be directly exposed to the weather while optimizing the lifespan of the insert element.

[0015] Thermal conductivity describes the rate at which heat dissipates from the interior of an insert element. For example, deformation of the insert element and the resulting flexural work can generate heat within it. If this heat is not dissipated, it can lead to thermal failure due to carbonization. If a layer (e.g., a secondary layer and / or a primary layer) is designed to have increased thermal conductivity, the generated heat can be easily dissipated from the interior of the insert element. Therefore, thermal failure of the insert element can be avoided. Furthermore, layers with increased thermal conductivity are only needed where temperature peaks are likely to occur within the insert element. Preferably, layers with increased thermal conductivity can be placed in environments with regions exhibiting high temperature peaks. In this way, heat dissipation is effectively achieved and thermal failure is avoided. The remaining areas of the insert element can be provided with layers possessing other properties. This ensures safe operation even under thermal stress and provides an insert element optimized for other properties.

[0016] Preferably, the insert element further includes a core layer disposed on the side of the second insert element, wherein the core layer differs from the main layer and / or the secondary layer in at least one material property. The core layer may be a third layer, having different properties compared to the main layer and / or the secondary layer. For example, the core layer may be in contact with a substrate and may be optimized to secure the insert element to the substrate. In other words, the core layer may be designed to secure the insert element to a substrate, such as a structure or a rim. For example, the core layer may be designed such that it can apply a clamping force to the rim and thus securely hold the insert element to the rim.

[0017] Preferably, the secondary layer extends at least partially along the width direction in the cross-section. In other words, the secondary layer may be provided only partially along the width direction. This means that the material properties of the secondary layer can be specifically provided at designated points in the cross-section of the insert element. For example, the secondary layer may have increased thermal conductivity. If the secondary layer is then disposed only adjacent to the central region of the insert element, it can dissipate heat from there to the surrounding region. It is also conceivable that the secondary layer has greater rigidity than the primary layer and thus can support specific areas in the cross-section of the insert element. This can prevent the insert element from excessively deforming under external forces.

[0018] Preferably, the insert element can have a geometry for holding and guiding elements, particularly ropes or cables. The geometry can correspond to the shape of the element to be guided. This increases the contact surface between the element to be guided and the insert element. Furthermore, it ensures that, in the case of a rope or cable, it is safely guided within a specific area of ​​the insert element. The geometry could, for example, be an approximately semi-circular cut on the side of the first insert element. The rope can then rest against this cut.

[0019] Preferably, the secondary layer extends only in the width direction within the cross-section of the geometry. The fact that the rope guided by the insert element is stationary within the geometry (i.e., has a fixed position in the width direction) causes the insert element in this region to bear particularly high loads. This can be addressed by providing a secondary layer in the width direction, specifically only in this region. For example, a secondary layer with optimized stiffness can be provided only in the width direction within the geometry. In this case, the secondary layer can be positioned within the insert element at a distance from the side of the first insert element. Since, for example, the secondary layer has higher stiffness compared to the primary layer, the flexural work introduced into the insert element can be reduced or avoided, thereby reducing the heat input to the insert element. A primary layer with, for example, sound suppression and / or vibration suppression properties can be provided around the secondary layer. This can produce a particularly durable insert element with very good suppression properties. Optimized stiffness can be understood as the maximum possible stiffness without achieving vibration and / or suppression properties.

[0020] Preferably, the secondary layer is disposed adjacent to the geometry in cross-section. In other words, the geometry may be formed only in the secondary layer. In this embodiment, the secondary layer may be disposed on the side of the first insertion element. In other words, the secondary layer may be disposed on the surface of the insertion element. It is advantageous if the secondary layer has a specific coefficient of friction and / or abrasion resistance, which is beneficial in terms of the durability of the insertion element that is in direct contact with the rope or cable to be guided.

[0021] Preferably, the secondary layer is located at the lowest point of the geometry. In other words, the secondary layer may be provided only in sections of the geometry. Depending on the geometry of the rope and lining, the highest load sometimes occurs at the lowest point of the geometry. Therefore, it is advantageous to reinforce this area specifically with a secondary layer having corresponding properties. For example, a particularly hard material may be provided in the area around the lowest point. This can increase the overall durability of the insert element.

[0022] Preferably, the secondary layer extends at least partially in the radial direction in the cross-section. In other words, the secondary layer may only be provided partially in the radial direction in the cross-section. Thus, the secondary layer may be surrounded by the primary layer in the radial direction. This allows properties to be provided inside the insert element without the secondary layer coming into contact with the environment on the surface of the insert element. This is advantageous, for example, if the secondary layer is particularly susceptible to weathering or similar factors.

[0023] Preferably, the insert element further includes a fiber-reinforced inner layer disposed on the side of the second insert element. The inner layer can advantageously be used to secure the insert element to the rim. Furthermore, the fiber-reinforced inner layer can provide overall stability to the insert element.

[0024] Preferably, the primary and / or secondary layers comprise at least one elastomer based on SBR, BR, NR, IR, EPM / EPDM, IIR / X-IIR, NBR, HNBR, CR, PE, PP, CPE, PVC, CSM, and / or combinations thereof. SBR (styrene-butadiene rubber) can exist, for example, in the form of emulsion and solution SBR and / or high-styrene SBR. SBR can possess good mechanical properties, excellent abrasion resistance, and good resistance to permanent deformation. SBR is also well resistant to Freon, ethylene glycol, and brake fluid. BR (butadiene rubber) has excellent elastic properties, good abrasion resistance, and is particularly easy to blend with SBR, NR, IR, and NBR. BR also has moderate resistance to seawater, acids, and alkalis. NR (natural rubber) has excellent mechanical properties, very good elastic properties, and good abrasion resistance. NR has moderate resistance to seawater, acids, alkalis, and other medium-concentration media. IR (polyisoprene rubber) has good mechanical resistance, good elastic properties, and is particularly suitable for blending with SBR and NR. IR also exhibits moderate resistance to seawater, acids and alkalis, and moderate concentrations of media. EPDM (ethylene propylene diene monomer rubber) possesses excellent heat resistance, high-temperature resistance, and ozone resistance, and high resistance to permanent deformation. EPDM also shows good resistance to water, ethylene glycol, and corrosive chemical oxidation. NBR (nitrile butadiene rubber) has good oil resistance, good mechanical properties, and good to excellent gas and air permeability. HNBR (hydrogenated nitrile butadiene rubber) has very good mechanical properties, very good heat resistance (up to 51°C), excellent abrasion resistance, and excellent resistance to permanent deformation. CR (chloroprene rubber) has good ozone and seawater resistance, good flame retardancy, and good resistance to animal and vegetable oils. EE (polyethylene) is highly resistant to acids, alkalis, solvents, and other chemicals. PE also has good electrical insulation properties and good sliding properties. In contrast, its mechanical properties are only moderate. PP (polypropylene) has good electrical insulation properties. CPE (chlorinated polyethylene rubber) has particularly good aging resistance and ozone resistance. PVC (polyvinyl chloride) is particularly easy to process. CSM (chlorosulfonated polyethylene) possesses excellent mechanical properties, very good flame retardancy and heat resistance, ozone resistance and weather resistance, and excellent gas and air permeability. CSM is highly resistant to strong oxidants and exhibits excellent resistance to brine, salt solutions, alcohols, and hydrochlorides. Due to the above material options, the primary and secondary layers can be made from appropriate materials or combinations of several materials, depending on their application and desired properties. SBR, BR, and NR, or combinations thereof, are particularly preferred. The primary layer may include BR as the main material. BR provides excellent dynamic properties and low abrasion. The primary layer may also include NR. The secondary layer may include SBR and NR as the main materials. Furthermore, the secondary layer may include BR and fillers.

[0025] Preferably, the primary and / or secondary layers comprise TPA, TPC, TPO, TPS, TPU, TPV, or crosslinked olefin-based thermoplastic elastomers, rubber-synthetic resin blends, PTFE, and / or combinations thereof. TPA describes thermoplastic polyamide elastomers, TPC (thermoplastic copolyester elastomers), TPO (olefin-based thermoplastic elastomers), primarily PP / EPDM, TPS (thermoplastic styrene block copolymers such as SBS, SEBS, SEPS, SEEPS, and MBS), TPU (polyurethane-based thermoplastic elastomers), or TPV (thermoplastic vulcanizates).

[0026] Preferably, the main layer may be formed of an elastomer and the secondary layer of a thermoplastic, or the main layer may be formed of a thermoplastic and the secondary layer of an elastomer. For other layers, in the overall composite material, at least one polymer and at least one elastomer layer may be advantageous. These combinations also have the effects of extending life, optimizing wear or vibration, or optimizing conductivity.

[0027] Preferably, the insertion element includes a reinforcement in the form of fibers, threads, ropes, or fabrics made of glass, carbon, rock wool, metal wool, titanates, aluminum silicates and alumina, ceramics, silicon carbide, iron and copper and their alloys, polyamide, polyacrylonitrile, polyester, phenol, aramid, cotton, cellulose, and / or combinations thereof. The reinforcement can be added to achieve specific properties of the primary and / or secondary layers. Preferably, the reinforcement is disposed adjacent to the first insertion element side. The reinforcement may be disposed only on the first insertion element side. This can prevent or reduce localized deformation of the insertion element upon contact with the element to be guided (e.g., a rope).

[0028] Preferably, the secondary layer has a circular or elliptical cross-sectional shape. In other words, the geometry of the secondary layer can further enhance and / or precisely achieve the desired characteristics to be realized through the secondary layer. For example, an elliptical cross-section can provide greater resistance to deformation. Furthermore, specific areas in the cross-section of the insert element where specific loads (e.g., flexural motion) occur can be specifically covered with the secondary layer to achieve the desired characteristics locally.

[0029] Preferably, the primary and / or secondary layers have a conductivity of <100 Ohm x cm. This means that at least one of the layers can be implemented as a conductive layer. This makes potential equalization possible. Therefore, the copper brush or similar material that contacts the rope to be guided, as used in the prior art, can be omitted, and the corresponding characteristics can be provided by the insertion element. Furthermore, the primary and / or secondary layers can also be insulated. This is particularly advantageous if signals are to be transmitted through the rope (e.g., a cableway). Such signals can then be received by a signal pickup. Insulated insertion elements facilitate interference-free signal transmission through the rope.

[0030] Preferably, the insert element includes a third layer that differs from the main layer and / or the secondary layer in at least one material property. The third layer can be used to achieve other properties in the insert element. The third layer is suitable for the same design options as the main and secondary layers. Furthermore, a fourth layer can also be provided. With such a fourth layer, which can differ from the main, secondary, and / or third layers in at least one material property, further desired properties can be achieved with the insert element. Therefore, a three-layer structure for the insert element can be provided. However, more layers can also be provided. For example, a fourth layer can be provided, thus achieving a four-layer structure for the insert element. In general, a large number of layers can be provided. Each of the layers can be designed individually to achieve the desired properties of the insert element as a whole. In other words, each of the layers can have embodiments of the main and / or secondary layers described herein.

[0031] Preferably, the secondary layer has sound-absorbing properties. For example, minimizing downtime is particularly important for cableway facilities in urban areas. In urban areas, 24 / 7 operation can be assumed, meaning environmental conditions differ from those in applications such as high-altitude mountainous regions. In other words, a 30,000 km lifespan for the guide rope in urban use might necessitate multiple replacements of the insert element each year, incurring corresponding costs. Furthermore, the requirements for sound absorption are much higher. Therefore, the problem of sound transmission can be addressed by providing a secondary layer with special sound-absorbing properties. The secondary layer can comprise a softer material than the primary layer. The primary layer can ensure the necessary lifespan by using a harder or more abrasion-resistant material.

[0032] Preferably, the secondary layer can be designed as a weather-resistant cover. In the prior art, weather-resistant layers on insert elements often negatively impact other characteristics of the insert element, leading to problems with durability and / or noise transmission. Since, in one embodiment of the invention, only the secondary layer can be weather-resistant, the primary layer can accordingly ensure the provision of other characteristics for the insert element. Therefore, the insert element as a whole can have a longer service life.

[0033] Preferably, the secondary and primary layers are detachably connected to each other. Where the inner layer (e.g., the secondary layer) can be made of a more durable material, the outer layer (e.g., the primary layer) can be replaced when it wears out, as the inner layer remains usable. In other words, by using an optimized core material, the core material can be used for a longer period compared to the case where a homogeneous insert liner is typically used. This means that the overall service life can be advantageously increased by applying a new cover layer. Different areas of the insert element can be reused according to refurbishment techniques. Separability between the primary and secondary layers can be provided, for example, through a separation layer. Furthermore, the secondary and primary layers can also be bonded to each other, and during replacement, the layer to be removed can be, for example, milled or turned. It is also conceivable that the secondary and primary layers are connected to each other in a form-fit and / or force-fit manner. This makes replacement particularly easy.

[0034] Preferably, the secondary layer and / or the primary layer has at least one cavity. At least one cavity in the insert element can provide a favorable clamping force on the rim.

[0035] Preferably, the main layer extends more radially than the secondary layer. In other words, the main layer can be thicker than the secondary layer in either the radial or vertical direction. Therefore, a longer service life can be achieved when the main layer is positioned on the side of the first insertion element and thus in contact with the rope or cable to be guided. In this case, the secondary layer can have sound-absorbing or emission-suppressing properties. Both objectives—reducing emissions and increasing durability—are thus achieved.

[0036] Preferably, the insert element is designed as a ring-shaped insert element, and preferably the ratio of the inner diameter to the outer diameter is 0.3 to 0.9, particularly 0.7 to 0.85. The first range has proven particularly advantageous when the insert element is used in high-altitude areas for cable cars. The range of 0.7 to 0.85 has proven particularly advantageous in reducing noise emissions, which is why such insert elements are particularly suitable for urban or noise-controlled areas.

[0037] Preferably, the radial extension length of the primary layer is 10% to 90% of the radial extension length of the secondary layer, more preferably 20% to 80%. In the first range, it is found that only a very small portion of the energy introduced into the insert element is converted into heat, and the remainder is released again as kinetic energy. In this case, the secondary layer can be surrounded by the primary layer. In this case, the secondary layer can be disposed radially inside the insert element. This allows for dynamic characteristics under load on the insert element, enabling the energy introduced into the system to dissipate again, and advantageously, generating very little heat. Therefore, localized temperature spikes inside the insert element can be avoided, thus preventing thermal failure due to carbonization. Preferably, by introducing the secondary layer across the entire cross-sectional width, particularly in the dynamic stress region below the contact point between the insert element and the element to be guided, the heat input to the insert element can be reduced or minimized. In the second range, it has been shown that the insert element has an increased service life even under dynamic loads.

[0038] Preferably, the ratio of the extension length of the primary layer in the width direction to the extension length of the secondary layer in the width direction is 1.1 to 2.5. In other words, the secondary layer may be provided only partially in the width direction. This is particularly advantageous if the contact area between the insert element and the element to be guided is designed to be replaceable. In other words, the primary layer can be retained, while only the secondary layer provided partially in the width direction is replaced. In this way, a particularly environmentally friendly insert element that is at least partially recyclable can be achieved.

[0039] The preceding sections first described the primary and secondary layers. However, more layers can also be provided. For example, a third layer can have similar characteristics and / or design to the primary or secondary layers.

[0040] With the growing demand for sustainable products, the multi-layered structure of insert elements can help reduce the need for high-performance materials with essential raw materials, allowing the use of more sustainable but potentially less resilient materials. Furthermore, it enables efficient and effective separation of recyclable and non-recyclable materials. Additionally, "green" raw materials can be used in multi-layered insert elements, and the recycling of insert elements can be facilitated more easily.

[0041] The previous section mainly described two-layer insert elements, but multiple layers (e.g., three or more layers) can also be provided.

[0042] According to another aspect of the invention, a roller system is provided, particularly a roller system for guiding ropes or cables, especially for guiding ropes or cables of cableway facilities, comprising a rim and an insertion element according to one of the foregoing embodiments, wherein the insertion element is mounted on the rim such that the insertion element can rotate together with the rim.

[0043] According to another aspect of the invention, a method for manufacturing an insert element is provided, particularly a method for manufacturing an insert element for guiding ropes or cables, especially a method for manufacturing an insert element for guiding ropes or cables in cableway facilities, comprising the steps of: providing a primary layer and a secondary layer, the primary layer and the secondary layer differing in at least one material property; and joining the primary layer and the secondary layer by compression molding, injection molding, extrusion, casting, winding, printing and / or vulcanization. Preferably, in the above method, the insert element is manufactured according to any of the above embodiments. Preferably, the method further includes mechanically remachining the insert element by turning or milling.

[0044] The various features of an embodiment can be combined with other features or other embodiments to form new embodiments. The embodiments and advantages associated with a particular embodiment or feature also apply to the new embodiments. The embodiments and advantages associated with a device also apply to the method, and vice versa.

[0045] Preferred embodiments will now be described in detail with reference to the accompanying drawings.

[0046] The diagram shows:

[0047] Figure 1 A perspective schematic view of an insert element according to an embodiment of the present invention is shown.

[0048] Figure 2 A schematic cross-section is shown through a portion of the insert element according to an embodiment of the invention.

[0049] Figures 3a and 3b show schematic cross-sections of an insert element according to an embodiment of the present invention.

[0050] Figures 4a to 4c each show a schematic cross-section through an insertion element according to an embodiment of the present invention.

[0051] Figures 5a and 5b show schematic cross-sections through an insert element according to an embodiment of the invention, and

[0052] Figure 6 A flowchart of a method for manufacturing an insert element according to an embodiment of the present invention is shown.

[0053] Inserted components are typically considered safety parts and adhere to strict acceptance standards. The typical maximum generating and acceptable surface pressure in profiles is 6 N / mm². 2 For high-load insertion components, up to 9 N / mm is also allowed. 2 Surface pressure. For values ​​higher than this, up to 20 N / mm. 2The conditions under which these conditions are expected to reduce lifespan are tested through finite element simulation, dynamic testing on a test bench, or dynamic testing of the system itself. The lifespan of the insert element is typically specified in kilometers of the guiding rope. However, specifications also exist for operating time. The loads mentioned here include rope force, normal force, surface pressure, rope and insert element geometry, system operating speed, environmental conditions, clamping / installation force, and insert element dimensions, as well as insert element material data / material properties, and maintenance and inspection specifications. Nevertheless, the insert element is a wear component in rope-guided or track-guided systems, where various causes of wear and failure are known.

[0054] Insert elements are typically replaced due to wear or surface cracks. Standards specified by the system manufacturer or those outlined in the standard apply. Wear occurs when material on the insert element's "profile base" or flanks is removed by relative movement between the insert element and the rope / rail, combined with "misalignment" or "tracking" of the rope on the insert element. Therefore, wear is measurable. Vibration or impact, or an inappropriate rope diameter, can also lead to excessive wear. Cracks are caused, for example, by material aging or mechanical overload. Other types of breakage include material damage caused by oil and grease, ring slippage, cracks (also due to excessively tight press fits on the pulley body), breakage due to misaligned rope guidance, and similar causes.

[0055] Current technologies utilize materials that represent trade-offs between target values, such as dynamic properties (heat generation), mechanical properties (wear), electrical conductivity, noise emissions, frictional and braking properties, and weather resistance. The composition of the mixture, along with the current structure and geometry of the insert element, is sufficient for most use cases to date.

[0056] Figure 1 This is a schematic perspective view of an insertion element 1 according to an embodiment of the present invention. The insertion element 1 has a first insertion element side 4 and an opposing insertion element side 6. Furthermore, the element in this embodiment is designed as a ring-shaped insertion element and is designed to rotate about a rotation axis D. Additionally, the insertion element 1 has a geometry 7 on the first insertion element side 4. This geometry corresponds in cross-section to the shape of the element to be guided. In this embodiment, the rope (not in...) Figure 1 (As shown in the diagram) Guided by inserting element 1. The geometry 7 is designed according to the rope to be guided.

[0057] Figure 2 It runs through Figure 1 The cross-section of the inserted element 1. More precisely, Figure 1The insert element 1, together with the rim 10, forms a roller system 100 according to an embodiment of the invention. Furthermore, the element 8 to be guided, in this example, is a rope, shown in cross-section. The cable 8 rests within the geometry 7 of the insert element 1. Figure 2 In the illustrated embodiment, the guide direction extends into the drawing plane.

[0058] Figure 3a is a cross-section through an insertion element 1 according to an embodiment of the invention. The insertion element 1 has a primary layer 2 and a secondary layer 3. The primary layer 2 and the secondary layer 3 differ from each other in at least one material property. Furthermore, a geometry 7, designed to contact and guide the rope, is visible on the first insertion element side 4. The radial or vertical direction R and the width direction B are also shown. The secondary layer is provided only in the region of geometry 7 along the width direction B. In this embodiment, the secondary layer has a dynamically optimized material that introduces very little heat energy to the insertion element due to the load. More precisely, the secondary layer 3 is designed to result in less rolling work, which significantly reduces the heat energy introduced into the insertion element 1. Due to the material design, the dynamically introduced energy is released again. This means that thermal failure due to carbonization in the radial direction, more precisely below geometry 7, can be avoided because little or no heat energy is introduced into the insertion element through the pressure of the rope. Furthermore, the insertion element of this embodiment has a reinforced inner layer 9 designed to contact the rim. This allows the insertion element 1 to be secured to the rim particularly reliably.

[0059] Figure 3b is a schematic cross-section through the insert element 1 according to another embodiment of the invention. The difference from the embodiment shown in Figure 3a is that the secondary layer 3 extends along the entire width of the insert element 1 in the width direction. Therefore, the effects of the previously described embodiments can be achieved across the entire width of the insert element 1 in the width direction B. This is particularly advantageous if the exact contact point between the insert element 1 and the element to be guided is not predetermined. Another advantage of this structure is that the secondary layer can be inserted more easily during lining manufacturing.

[0060] Figure 4a is a schematic cross-section through the insert element 1 according to an embodiment of the invention. In the embodiment shown in Figure 4a, the mechanical optimization of the insert element 1 is achieved at the interface with the rope. Therefore, significantly less wear and breakage behavior of the cover layer can be achieved. Depending on the manufacturing process, there are several options for positioning the mechanically optimized cover layer. In Figure 4a, the secondary layer 3 is located at the rope base of geometry 7. Depending on the rope and lining geometry, the highest load sometimes occurs at the rope base, meaning that maximum service life extension can be achieved here by providing particularly durable materials.

[0061] Figure 4b illustrates another embodiment of the invention, wherein a wear-resistant secondary layer 3 is disposed over the entire outer region of the insert element. This is particularly advantageous if other contact surfaces besides geometry 7 may also sometimes be present. Furthermore, the secondary layer 3 can have weather-resistant properties, meaning that the insert element can have an increased service life even under adverse weather conditions.

[0062] In Figure 4c, the secondary layer 3 is used as a lining for geometry 7 to provide mechanical reinforcement or wear resistance.

[0063] Overall, in all embodiments shown in Figures 4a to 4c, the contact surface between the rope and the insertion element is lined with a wear-resistant secondary layer 3.

[0064] Figure 5a illustrates another insertion element 1 according to another embodiment of the present invention. In this embodiment, the insertion element 1 includes a secondary layer 3 that has optimized conductivity throughout the entire outer region (i.e., on the first insertion element side 4). This achieves advantageous signal transmission performance of the insertion element 1. Furthermore, the primary layer 2 of this embodiment has improved dynamic strength.

[0065] Similarly, the third layer can also provide the desired insulation.

[0066] Figure 5b illustrates another embodiment of the invention, in which the secondary layer 3 can be updated in a simple manner. Here, for example, it is sufficient to update only the secondary layer around or adjacent to the geometry 7. It is also conceivable that the entire segment of the insert element facing the first insert element side is also updated.

[0067] Figure 6 This is a flowchart schematically illustrating the process sequence of a method for manufacturing an insert element according to an embodiment of the present invention. In step S1, a primary layer 2 and a secondary layer 3 are provided, wherein the primary layer 2 and the secondary layer 3 differ in at least one material property. In step S2, the primary layer 2 and the secondary layer 3 are bonded together by compression molding, injection molding, extrusion, casting, winding, printing, and / or vulcanization.

[0068] Step S3 is an optional step and includes mechanical remapping of the inserted element by turning or milling.

[0069] List of reference numerals

[0070] 1. Inserting elements

[0071] 2. Main Layer

[0072] 3rd layer

[0073] 4 First Insertion Element Side

[0074] 6 Second Insertion Element Side

[0075] 7. Geometric Shapes

[0076] 8 Components to be guided

[0077] 9. Reinforced inner layer

[0078] 10 rims

[0079] 100 Roller System

[0080] D. Rotation axis

[0081] R radial direction

[0082] B Width direction

Claims

1. An insertion element (1), particularly an insertion element for guiding ropes or cables, especially for guiding ropes or cables in cableway installations, comprising: Main layer (2), and The secondary layer (3) is disposed in and / or on the primary layer (2). in, The insertion element (1) has a first insertion element side (4) and a second insertion element side (6) opposite to the first insertion element side (4), the first insertion element side being designed to contact the element (8) to be guided, particularly a rope or cable, in the guiding direction, particularly in the circumferential direction. The main layer (2) and the secondary layer (3) differ in at least one material property. The insertion element (1) has a substantially constant cross-section along the guiding direction, and The insertion element (1) extends in the cross-section along the radial direction (R) and the width direction (B), respectively orthogonal to the guiding direction and to each other.

2. The insertion element (1) according to claim 1, wherein, The main layer (2) and the secondary layer (3) are each formed as an elastomer layer.

3. The insertion element (1) according to claim 1 or 2, wherein, The secondary layer (3) is at least partially disposed on the side of the first insertion element (4).

4. The insertion element (1) according to any one of the preceding claims, wherein, The at least one material property includes wear resistance, heat generation, electrical conductivity, sound suppression, vibration suppression, coefficient of friction, weather resistance, and / or thermal conductivity.

5. The insertion element (1) according to any one of the preceding claims, wherein, The insertion element (1) further includes a core layer disposed on the side (6) of the second insertion element, wherein the core layer differs from the main layer (2) and / or the secondary layer (3) in at least one material property.

6. The insertion element (1) according to any one of the preceding claims, wherein, In cross-section, the sublayer (3) extends at least partially along the width direction (B).

7. The insertion element (1) according to any one of the preceding claims, wherein, The insertion element (1) has a geometry (7) for receiving and guiding elements (8), particularly ropes or cables.

8. The insertion element (1) according to claim 7, wherein, The sublayer (3) extends in the cross-section only along the width direction (B) in the region of the geometry (7).

9. The insertion element (1) according to claim 7 or 8, wherein, In cross-section, the sub-layer (3) is arranged adjacent to the geometry (7).

10. The insertion element (1) according to any one of claims 7 to 9, wherein, The sub-layer (3) is located at the lowest point of the geometry (7).

11. The insertion element (1) according to any one of the preceding claims, wherein, The sublayer (3) extends at least partially in the radial direction (R) in the cross-section.

12. The insertion element (1) according to any one of the preceding claims, wherein, The insertion element (1) further includes a fiber-reinforced inner layer (9) disposed on the second insertion element side (6).

13. The insertion element (1) according to any one of the preceding claims, wherein, The main layer (2) and / or the secondary layer (3) comprises at least one elastomer and / or thermoplastic based on SBR, BR, NR, IR, EPM / EPDM, IIR / X-IIR, NBR, HNBR, CR, PE, PP, CPE, PVC, CSM and / or combinations thereof.

14. The insertion element (1) according to any one of the preceding claims, wherein, The main layer (2) and / or the secondary layer (3) include TPA, TPC, TPO, TPS, TPU, TPV or cross-linked olefin-based thermoplastic elastomers, rubber-synthetic resin mixtures, PTFE and / or combinations thereof.

15. The insertion element (1) according to any one of the preceding claims, wherein, The main layer (2) is formed of an elastomer, and the secondary layer (3) is formed of a thermoplastic, or wherein the main layer (2) is formed of a thermoplastic, and the secondary layer (3) is formed of an elastomer.

16. The insertion element (1) according to any one of the preceding claims, wherein, In cross-section, the sublayer (3) has a circular or elliptical cross-sectional shape.

17. The insertion element (1) according to any one of the preceding claims, wherein, The insertion element (1) includes a reinforcement in the form of fibers, filaments, ropes or fabrics made of glass, carbon, rock wool, metal wool, titanate, aluminum silicate and alumina, ceramic, silicon carbide, iron and copper and their alloys, polyamide, polyacrylonitrile, polyester, phenol, aramid, cotton, cellulose and / or combinations thereof.

18. The insertion element (1) according to any one of the preceding claims, wherein, The sublayer (3) has a circular or elliptical cross-sectional shape in cross-section.

19. The insertion element (1) according to any one of the preceding claims, wherein, The main layer (2) and / or the secondary layer (3) have a conductivity of <100 Ohm x cm.

20. The insertion element (1) according to any one of the preceding claims further includes a third layer, which differs from the main layer (2) and / or the secondary layer (3) in at least one material property.

21. The insertion element (1) according to any one of the preceding claims, wherein, The secondary layer (3) has sound absorption properties.

22. The insertion element (1) according to any one of the preceding claims, wherein, The secondary layer (3) is designed as a weather-resistant covering.

23. The insertion element (1) according to any one of the preceding claims, wherein, The secondary layer (3) and the main layer (2) are detachably connected to each other.

24. The insertion element (1) according to any one of the preceding claims, wherein, The secondary layer (3) and / or the primary layer (2) include at least one cavity.

25. The insertion element (1) according to any one of the preceding claims, wherein, The main layer (2) extends in the radial direction (R) more than the secondary layer (3).

26. The insertion element (1) according to any one of the preceding claims, wherein, The insertion element (1) is designed as an annular insertion element (1), and wherein the ratio of the inner diameter to the outer diameter is preferably 0.3 to 0.9, particularly 0.7 to 0.

85.

27. The insertion element (1) according to any one of the preceding claims, wherein, The extension length of the main layer (2) in the radial direction (R) is 10% to 90%, preferably 20% to 80%, of the extension length of the secondary layer (3) in the radial direction (R).

28. The insertion element (1) according to any one of the preceding claims, wherein, The ratio of the extension length of the main layer (2) in the width direction (B) to the extension length of the secondary layer (3) in the width direction (B) is 1.1 to 2.

5.

29. A roller system (100), particularly a roller system for guiding ropes or cables, especially a roller system for guiding ropes or cables in cableway installations, comprising... Wheel rim (10), The insertion element (1) according to any one of the preceding claims, in, The insertion element (1) is mounted on the rim (10) such that the insertion element can rotate together with the rim (10).

30. A method for manufacturing an insertion element (1), particularly a method for manufacturing an insertion element for guiding ropes or cables, especially a method for manufacturing an insertion element for guiding ropes or cables in a cableway facility, comprising the following steps: Provides a main layer (2) and a secondary layer (3), wherein the main layer and the secondary layer differ in at least one material property, and The primary layer (2) is bonded to the secondary layer (3) by compression molding, injection molding, extrusion, casting, winding, printing and / or vulcanization.

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