Enhanced belt joint

Abstract

A method of forming a joint in a belt having a first end edge and a second end edge to be joined is disclosed. The method involves providing an aramid fiber section having a first edge and a second edge, for example as a discrete sheet. The first end edge of the belt is arranged to overlap the first edge of the fiber section from one side and the second end edge of the belt is arranged to overlap the second edge of the fiber section from the other side. The first end edge and the second end edge are joined to the fiber section in the arrangement to form a joint interface between the first end edge and the second end edge, where the aramid fiber section reinforces the joint. The adhesive may be used to bond the fiber segments to the belt material. Woven aramid fiber segments may be used. The fiber segments may be located between layers of the belt. Various belts having joints formed by the method are disclosed, including belts having splice joints or mechanical joints.

Description

TECHNICAL FIELD

[0001] The present application relates to a method of manufacturing a reinforced joint in a belt, particularly for conveyor belts where the joint is prone to failure. BACKGROUND

[0002] Endless belts are formed by looping a desired length of belt material and forming a joint such that a first end portion of the belt material is joined to an opposite second end portion. Common methods of joining include vulcanized / spliced joints, butt joints and mechanical fasteners.

[0003] It is common to join opposite end portions of a belt together as a hot-bonded splice. A common example of a splice involves cutting or stamping finger-like structures in the end portions of the belt and attaching the two end portions together such that the fingers on each end portion fit between the opposite fingers on the other end portion. The fingers are hot butted or bonded or butted or bonded using an adhesive. The strength of the connection is a direct result of the length and shape of the fingers. The interface between the belt end portions thus passes back and forth along the fingers, making it longer than the width of the belt and offset at an angle to the longitudinal axis of the belt. This type of joint can be referred to as a "Z-splice" or "finger splice". The joint can be subjected to temperature, pressure and / or adhesive.

[0004] Where the belt material comprises a plurality of layers, the fingers for different layers can be offset such that the joint interface for one layer is laterally and / or longitudinally offset from the interface for a different layer. This can be referred to as a "stepped Z-splice" or "finger-in-finger Z-splice".

[0005] Mechanical joints use fasteners such as clips, nails or screws to mechanically attach two opposite end portions of a belt together. The strength of the connection depends on the frequency and nature of the perforations made by the fastener material. However, a limitation of this method is that certain fasteners can only be applied to certain types of belt as particular types of fasteners are able to accommodate a limited range of belt thicknesses. The interface represents a discontinuity in the belt and the presence of a mechanical fastener can itself be problematic for smooth / continuous belt operation.

[0006] From the above discussion it will be appreciated that significant attention is given to the joint in order to ensure that it is suitable for the intended use of the belt. However, regardless of the method employed, the joint is always a potential weak point of the belt and the most likely point of failure over the operational life of the belt.

[0007] The tensile strength of the joint is a particular problem for endless PVC or PU conveyor belts, where contaminants accumulate and become embedded in the belt and on the rollers. The increased volume increases the diameter of the rollers, which puts the belt under greater tension and ultimately often leads to failure, usually at the joint. Another example of the belt failing under tension arises when the belt trajectory is misaligned, meaning that one lateral side of the belt is often periodically under greater tension than the other lateral side.

[0008] However, the tensile strength of the joint is only one engineering consideration. There are a wide variety of belt failure modes, including delamination (e.g. peeling of one or more layers at the joint) and belt perforation. In many cases, a small initial defect at the joint will grow over time by propagating along the joint interface.

[0009] It is estimated that approximately 85% of belt failures in industry occur at the joint. In some cases, the conveyor belt is repaired, but the cost of the repair and the likelihood of subsequent failure of the belt means that it is often more cost effective to fit a new belt.

[0010] For production and distribution facilities, a key operational consideration is the downtime of the production line caused by belt failure. To this end, replacement of the belt is often carried out on site and is often judged by the speed at which the belt supplier can make the replacement belt available.

[0011] The present situation therefore means that the vast majority of belts do not reach their natural end of life due to wear of the belt material itself, but are thrown away and replaced with a new belt prematurely due to failure of the joint.

[0012] Furthermore, conveyor belts are often made from hot-bonded and non-recyclable PVC or PU material, resulting in environmental waste that is sent to landfill. This is a particular problem for fulfilment centres, which can have many miles of conveyor belt passing through the centre at any one time.

[0013] When looking for a more environmentally sustainable solution, it is clear that the problem of discarded belts needs to be addressed. While so-called endless belts are known, their method of manufacture results in the belt being many times the cost of the jointed belts of the type described above.

[0014] It is an object of the present invention to alleviate or eliminate one or more of the above problems. SUMMARY

[0015] According to a first aspect of the application, there is a method of forming a reinforced joint in a belt, the belt having first and second end portions to be joined, the method comprising: providing a section of fibrous material having opposing first and second edges, such that the first end portion of the belt at least partially overlaps the first edge of the section of fibrous material and the second end portion of the belt at least partially overlaps the second edge of the section of fibrous material; and joining the first and second end portions to the section of fibrous material to form an interface between the first and second end portions, such that the section of fibrous material spans the interface.

[0016] According to a second aspect of the application, there is a method of forming a reinforced joint in a belt, the belt extending in a longitudinal direction, and the belt comprising first and second end portions to be joined at a joint, a discrete section of fibre being inserted at the joint and extending in the longitudinal direction, the first and second end portions being joined to the section of fibre.

[0017] According to a third aspect of the application, there is a method of forming a reinforced joint in a belt, the belt extending in a longitudinal direction, and the belt comprising first and second end portions to be joined at an interface, a section of fibre being inserted at the interface, the first and / or second end portions being joined to the section of fibre, wherein the length of the section of fibre is configured to extend a predetermined distance from the interface in the longitudinal direction from both the first and second end portions.

[0018] According to a fourth aspect of the application, there is a method for forming a reinforced joint in a belt as defined in claim 1.

[0019] According to a further aspect of the application, there is provided a belt or conveyor belt resulting from the method of any of the first, second or third aspects.

[0020] The resulting belt, and associated method, can result in a reinforced joint or interface region having greater strength than the remainder of the belt. Specifically, ensuring that fibres extend across the interface means that there is continuity between the first and second end portions (e.g. the end edges thereof) of the belt. The fibres provide a force path between the two end portions to be joined.

[0021] The section of fibre can span the interface. The section of fibre typically terminates on either side of the interface, such that there is no discrete section of fibre present in the remainder of the belt.

[0022] For example, a section of fibre can be present on either or both sides of the interface, e.g. in the direction of the first and / or second end portions.

[0023] The fibre segments can be continuous through the interface. The fibre segments can span the interface.

[0024] According to another aspect of the application, there is a belt comprising a segment of reinforcing fibres at a joint in the belt, wherein the segment of reinforcing fibres is joined proximate to an end of the belt forming one side of the joint, the fibre segment has a discrete length in a longitudinal direction, and the belt is longer in the longitudinal direction than the fibre segment.

[0025] According to another aspect, there is provided a belt having a reinforced joint, the belt extending in a longitudinal direction and comprising a first end edge and a second end edge, the first end edge and the second end edge being joined at an interface to form a loop, wherein the belt comprises a ply of fibres at the interface, the ply of fibres being continuous across the interface such that the ply of fibres is continuous from the first end edge through the second end edge and terminates in the longitudinal direction of the belt at a location spaced apart from the interface, whereby the continuous segment of fibres extending across the interface reinforces the joint.

[0026] The ply of fibres can be referred to herein as a segment of fibres.

[0027] At least some of the fibres of the ply / segment can be oriented in a direction that is offset from the longitudinal direction of the belt. At least some of the fibres can be oriented in a transverse direction of the belt and / or obliquely (e.g. angularly offset from both the longitudinal direction and the transverse direction). The ply / segment of fibres can comprise both warp fibres and weft fibres, for example as a woven fabric ply / segment.

[0028] The reinforced joint can provide a stronger, more robust joint than the prior art. The joint can be less prone to failure and / or can withstand higher tensile loads. The fibre reinforced segment of the belt (i.e. in the vicinity of the joint) can have greater tensile strength and / or puncture resistance than the remainder of the belt.

[0029] The reinforced joint can increase the service and operating life of the belt, for example meaning reduced machine and operational downtime due to belt failure.

[0030] Increasing the operating life of the belt can mean reducing belt wastage.

[0031] The segment of fibres can be generally planar. The segment of fibres can comprise a body portion, which can be flat. The segment of fibres (e.g. the body portion thereof) can comprise first and second edges opposite one another, and can further have intermediate / side edges extending between the first and second edges. The segment of fibres (e.g. the body portion thereof) can be quadrilateral in shape, for example square, rectangular or parallelogram.

[0032] The segment of fibres can comprise a mat or web.

[0033] The fibre segment can comprise a composite structure. The fibre segment can comprise fibres in a matrix. The fibre segment can comprise a fibre ply and one or more other plies, for example one or more other plies above and / or below the fibre ply. The further plies can comprise a support ply, a backing or an adhesive ply. For example, the fibre segment can be provided in the form of a sheet or a block, for example with the fibre ply disposed on a backing ply.

[0034] The fibre segment (for example, a body portion thereof) can have substantially the same width or transverse dimension as the belt (for example, a first end edge or a second end edge thereof) or a belt body. The fibre segment can span a transverse dimension of the belt, for example, between opposing transverse sides of the belt. The fibre segment can not protrude beyond the transverse sides of the belt. In some examples, the width of the fibre segment can be narrower than the belt.

[0035] The fibre segment (for example, a body portion thereof) can or can not have a width or transverse belt dimension that is longer than its length or longitudinal belt dimension. Thus, on insertion, the fibre segment can extend substantially across an interface between the first end edge and the second end edge.

[0036] The fibre segment can have a dimension in the longitudinal direction of the belt that is substantially less than the length of the belt, for example at least one or two orders of magnitude shorter. The fibre segment can be only a few centimetres in length, relative to a belt that is at least a metre or tens of metres long. The fibre segment can extend less than 10 cm or 5 cm, for example less than 3 cm or 2 cm, in the longitudinal direction beyond the interface. The fibre segment can substantially match the longitudinal dimension of the interface.

[0037] The interface can be defined as a line, area or volume between the opposing end edges of the belt. The interface can be defined as a joint or line / area of contact between the first end edge and the second end edge. The interface can have a visible seam where the first end edge and the second end edge meet or overlap one another. The interface can be overlaid on the fibre segment, for example meaning that the interface is contained within the area, footprint or perimeter of the fibre segment (for example, the first major surface and / or the second major surface of the body portion). The seam and / or part of the interface can extend beyond the first edge or the second edge.

[0038] The first end and the second end of the belt can meet one another, and can also meet the fibre segment.

[0039] The interface (for example, a seam thereof) between the first end edge and the second end edge can follow a path / axis that is substantially perpendicular to the longitudinal direction of the belt. Alternatively, the path / axis of the interface can be angled relative to the longitudinal axis, for example obliquely angled, for example where the interface appears to extend diagonally across the width of the belt.

[0040] The interface can follow a tortuous path through the width of the belt. The end edges can be shaped / cut so as to define opposing formations or protrusions in the first and second end edges. The opposing formations can interlock or interpose at the interface. The formations can comprise fingers / wedges (e.g., dovetail formations).

[0041] The belt can have a first and second major / opposing faces (e.g., upper and lower faces). For example, the fiber segment can be located between the first and second faces of the belt, e.g., within the depth or material thickness of the belt. In some embodiments, a recess or groove can be formed in the depth of the belt, adjacent the end edges of the first and / or second ends, e.g., so as to accommodate the depth of the fiber segment within the depth of the belt. For example, the depth of the recess can correspond to (or be the same as) the thickness / depth of the fiber segment. This can help avoid the fiber segment significantly increasing the belt depth near the interface.

[0042] The interface can have a zig-zag appearance. The interface can follow a path that varies relative to the interface axis, e.g., oscillates or meanders back and forth relative to the interface axis.

[0043] The fiber segment (e.g., the body portion thereof) is a discrete or discontinuous piece (e.g., terminates partially at the interface or terminates a short distance along the length of the belt), such that it does not extend through the longitudinal length of the belt. The fiber segment is located near the interface. The fiber segment can extend partially in the direction of the first and / or second end edges or beyond the first and / or second end edges in the longitudinal direction. In some embodiments, the fiber segment can be positioned continuously or substantially continuously through the belt and / or integrally formed into the belt.

[0044] The first and / or second ends can comprise a plurality of plies or layers. The fiber segment can be inserted between the layers or plies.

[0045] The method can include forming or separating a plurality of layers in the first and / or second ends of the belt. The method can include partially separating the belt between the upper and lower surfaces of the belt in the depth dimension of the belt. The method can include separating the first and / or second ends or the layers in the first and / or second ends only over a predetermined / limited length of the belt near the ends.

[0046] In some embodiments, the layers or plies of the belt are partially separated at the end edges for insertion or attachment of the fiber segment; a majority or middle section of the belt length can not be separated. The fiber segment can not extend into the middle section of the belt. When the belt is formed as an endless belt, the fiber segment is not endless, e.g., the first and second edges of the fiber segment do not join as a loop.

[0047] Bringing the fiber segments close to or proximate the joint strengthens the thinnest part of the belt and reduces weight, complexity, and manufacturing cost since all of the belt does not have to be strengthened.

[0048] One or more fiber segments can be inserted between one or more layers and the end edges can then be cut to form the desired configuration / profile in the end edges (i.e., the interface when joined). The first and second end edges are joined to the fiber segments and / or other end edges.

[0049] The fiber segments can be fused, bonded, or attached to the first and / or second end of the belt. The fibers or fiber plies can be bonded using an adhesive. The fiber segments can include an adhesive layer.

[0050] Heat and / or pressure can be applied to the fiber segments in situ with the first and / or second end of the belt. The adhesive can melt between the fibers and the material of the belt to bond the fiber segments to the belt. A continuous adhesive layer can be disposed over the area of the fiber segments. The fibers can be sandwiched between a pair of adhesive layers.

[0051] A predetermined elevated temperature and / or pressure can be maintained for the joint treatment / configuration, e.g., for a predetermined time. The opposing ends of the belt and fiber reinforcement can be held in a press.

[0052] The treatment can include heating the belt between 80°C - 250°C, optionally between 120°C - 200°C, optionally between 150°C - 170°C.

[0053] The heat / pressure treatment can be applied for up to 1 hour, optionally up to 30 minutes, optionally up to 10 minutes, optionally up to 5 minutes, optionally up to 2 minutes, optionally up to 1 minute. The treatment can be at least up to 1 minute, optionally at least 2 minutes, optionally at least 5 minutes, optionally at least 10 minutes, optionally at least 30 minutes, optionally at least to 60 minutes. The listed durations can alternatively be used to form an appropriate range of durations for the duration of the treatment (e.g., between 10 minutes - 30 minutes).

[0054] The treatment pressure can be at least 0.1 bar, e.g., at least 0.2 bar, 0.5 bar, 1 bar, 2 bar, 5 bar, or at least 10 bar, optionally at least 20 bar. The treatment pressure can be less than or equal to 20 bar or 10 bar, e.g., less than or equal to 8 bar, 5 bar, 2 bar, 1 bar, 0.5 bar, or 0.2 bar. The listed pressures can alternatively be used to form an appropriate range of pressures (e.g., between 0.1 bar - 10 bar or 2 bar - 5 bar).

[0055] The fiber segments can comprise fibers that are capable of withstanding high tensile loads. The fiber segments can comprise para-aramid fibers, such as Kevlar (registered trademark). The fibers can comprise other types of aramid fibers, such as meta-aramids. The fiber segments can comprise carbon fibers, nylon, glass, or graphene fibers. The fiber segments can comprise a mixture / blending of different combinations of fibers.

[0056] The fibers can be provided in the form of a fabric ply, such as a mat, web, mesh, or net. The fibers can be interwoven, knitted, or woven or applied to a foil / support ply. The fabric ply can be an open fabric ply, for example, having openings / holes between the fibers or fiber bundles (which can be suitable for use as a keying location as discussed below).

[0057] The fibers can be arranged in a regular pattern. The fiber bundles can be arranged in a regular pattern. The fiber ply of fiber segments can have a mouth opening (for example, as an open weave / pattern) or can comprise a closed or tight weave / pattern. The fibers can be arranged in an irregular or random configuration. The fiber ply can have a mesh-like appearance such that it is partially transparent.

[0058] The fiber ply (i.e., the fibers) or body portion can be woven to form a weave, for example, woven into an open or closed weave. An open weave will be understood to mean that there are many openings in the weave. The weave can be defined by a porosity (i.e., the percentage / ratio of fibers to gaps (relative to the major surface)).

[0059] The fabric can have a porosity of greater than 95%, or greater than 90%, or greater than 85%, or greater than 80%, or greater than 75%, or greater than 70%, or greater than 65%, or greater than 60%, or greater than 55%, or greater than 50%, or greater than 45%, or greater than 40%, or greater than 35%, or greater than 30%, or greater than 25%, or greater than 20%, or greater than 15%, or greater than 10%; with lower porosity corresponding to a more dense / tightly packed fabric. Any fabric pattern having a porosity of less than 10% can be defined as a closed weave. The type of weave, for example, the porosity of the fabric, can depend on the type of belt and / or the purpose of the belt. For example, a lower porosity weave can have a higher tensile strength than another more open weave made of the same material and would be better suited for a belt under higher tension.

[0060] The weave can be a flat weave, or a satin weave, or a twill weave, or a leno weave.

[0061] The fibers can extend generally in two or more directions in the fabric ply. For example, some fibers can extend in a direction generally parallel to a longitudinal axis of the belt, such as one of the warp or weft threads of a woven fabric. Some fibers can extend in a direction generally perpendicular to the longitudinal axis of the belt. Additionally or alternatively, the fiber section can include fibers that are generally angled (i.e. between 1 - 45 degrees) to the longitudinal axis of the belt. Optionally, the fiber section has fibers extending in a first angled direction and a second angled direction perpendicular to the first angled direction.

[0062] The fibers can be provided in an adhesive matrix, e.g. coated in an adhesive. The fibers can be partially or fully saturated in the adhesive. The fiber section can include an adhesive coating such that the fabric ply is at least partially coated in the top and / or bottom surface. The coating can generally enclose the fabric ply or fibers therein.

[0063] The adhesive can be capable of curing one or more times, e.g. two or more times. For example, the adhesive can be reusable, becoming at least partially tacky after curing or hardening. The adhesive can be a thermoplastic capable of being reset. When the belt is composed of PVC or PU material, the adhesive is configured to bond the fibers to the PVC or PU material of the belt.

[0064] The adhesive can be flexible once cured or hardened. In use, e.g. when the conveyor belt is moving around a roller, the conveyor belt will bend. The adhesive can be configured to allow some flexibility without compromising the joint. For example, the adhesive can not be rigid and / or brittle.

[0065] References in this application to the adhesive of the fiber section being “cured” or “cured” are to be understood as referring to the adhesive having a first state and a second state, where the first state is harder or more tacky than the second state. In some embodiments, the first state can refer to the adhesive being a solid and the second state being a fluid; however, in some embodiments, both the first and second states can be fluids, where the first state is more tacky than the second state.

[0066] The coating can pass through one or more apertures in the body portion. The adhesive is capable of bonding the fibers of the body portion to the belt (e.g. the first and / or second end edges thereof).

[0067] The apertures can define "keying locations" whereby the belt material can penetrate the body portion of the fibre segment. The number of keying locations can depend on the structure of the fibres of the body portion, for example, a weave or porosity of the weave. The greater the porosity of the weave, i.e. the more open the weave, the more keying locations are available for the belt-like material to penetrate the fibre segment from above / below. For example, an open weave can have more porosity than a closed weave. Where the fibres of the body portion are non-woven, the keying locations are gaps between adjacent fibres or fibre bundles. In some embodiments, the keying locations can be added by piercing the body portion, which is particularly beneficial for closed weaves, among others, that do not have many apertures / keying locations by nature.

[0068] In some embodiments, the fibres can be 3D printed and can be printed directly into the desired pattern / weave.

[0069] The fibres of the fibre segment can be in an as-spun state, for example, before being covered with adhesive. Using as-spun fibres, i.e. untreated fibres, can improve the adhesive properties of the fibres, for example, forming a stronger bond with the adhesive.

[0070] The belt can comprise a plurality of segments joined together, i.e. using one or more reinforced joints. This is particularly beneficial for forming longer belts. By using a plurality of reinforced joints, the complexity and cost of manufacturing the belt can be reduced when compared to manufacturing a bespoke longer belt.

[0071] The belt can comprise a polyvinyl chloride (PVC) and / or polyurethane (PU) material. The belt, for example, the belt body, can have a longitudinal axis or direction along which the belt can extend or elongate. The belt is much longer than the fibre segment, such that the fibre segment does not extend through the belt body.

[0072] The belt can be an endless belt, such as a conveyor or timing belt.

[0073] The belt can have an unrolled length of 1 m, 2 m, 5 m or more, for example, 10 m or more, 20 m or more, or 50 m or more (e.g. when the belt is not formed into an endless belt).

[0074] The belt width can be a width of 5 cm or more, for example, a width of at least 10 cm, 20 cm, 30 cm or 50 cm. The belt width can be up to or more than 1 m or 2 m.

[0075] The reinforced joint can comprise a mechanical fastener joining the first end edge to the second end edge. The fastener can comprise a pin, a clip, a pin, an eyelet or a combination thereof.

[0076] The reinforced joint can be able to withstand a tensile load equal to or greater than 2500 N, 2750 N, or 3000 N. The reinforced joint can have a tensile strength greater than or equal to 50 N / mm, 55 N / mm, or 60 N / mm. In some embodiments, the tensile strength is at least 70 N / mm or 80 N / mm.

[0077] The reinforced joint can have improved puncture resistance relative to a non-reinforced joint. The reinforced joint can withstand a puncture force of at least 600 N, 700 N, 800 N, 900 N, or 1000 N. The reinforced joint can provide a compressive stress of at least 10 MPa, 15 MPa, or 20 MPa. The puncture resistance of the reinforced joint can be greater than the puncture resistance of a mid-portion of the belt (i.e., separate from the joint).

[0078] According to another aspect of the application, there is a method of forming a reinforced joint in a belt, the belt comprising a first end portion extending along a longitudinal axis, the first end portion being joined to a discrete length of a fibrous section, wherein the belt and the fibrous section are partially overlapping at the first end portion at a predetermined distance.

[0079] The first end portion or the second end portion of the belt can be defined as an end edge. The belt can have two longitudinal edges, i.e., sides, which are substantially parallel to the longitudinal axis. The first end edge and / or the second end edge can extend between the longitudinal edges. The first end edge and / or the second end edge can extend perpendicular to the longitudinal axis or at an oblique angle thereto.

[0080] The first fibrous section can be provided at the first end edge. The second fibrous section can be provided at the second end edge. The mechanical fastener can pass from the first end edge to the second end edge. The mechanical fastener can extend through or pierce the first fibrous section and / or the second fibrous section.

[0081] According to another aspect of the application, there is a sheet material for forming a reinforced belt joint, the sheet material comprising a fibrous composite layer, the fibrous composite layer comprising a fabric, the fabric comprising aramid fibers provided in a binder matrix; wherein the binder at least partially covers the aramid fibers and is cured.

[0082] The fibrous composite layer can be provided on a support / base (e.g., a support / base ply or a film / foil) on either or both sides of the fabric ply.

[0083] According to another aspect of the application, there is a method of forming a fibrous section for a reinforced belt joint.

[0084] Any optional feature or aspect of any one aspect of the application defined above can be applied to any other aspect, where feasible. For the sake of conciseness, the optional features combinations have not been explicitly repeated.

[0085] Fibres referred to herein can also be referred to as fibre bundles, such as yarns. BRIEF DESCRIPTION OF DRAWINGS

[0086] Working embodiments of the application will now be described in more detail, by way of example only, with reference to the accompanying drawings in which:

[0087] Figure 1 (a) to (e) show schematic three-dimensional views of stages in the process of forming a joint in a belt.

[0088] Figure 2 A schematic longitudinal cross-sectional view through a joint is shown.

[0089] Figure 3 (a) and (b) show schematic plan views of example joints.

[0090] Figure 4 Alternative arrangements of joints are shown in longitudinal cross-section.

[0091] Figure 5 (a) and (b) show respective cross-sectional and plan views of alternative arrangements of reinforced joints. DETAILED DESCRIPTION

[0092] The application can be applied to any conventionally constructed belt, which typically comprises a belt core layer comprising a fabric / textile material, which is provided with a top and bottom face layer depending on the intended use of the belt. The belt body is generally flat, but profiled belts can be considered. The belt body typically has a width dimension which is significantly greater than the material thickness of the belt, and a length dimension which is significantly greater than the width dimension, for example where the width is at least an order of magnitude greater than the thickness and / or the length is typically an order of magnitude or more greater than the width. However, the specific belt dimensions depend on the intended belt use, and the belt can be made shorter / longer, narrower / wider and with varying thicknesses depending on its usage requirements.

[0093] The fabric material in the core of the belt can be selected to suit a variety of requirements, including belt tracking properties, load / elongation properties, static properties, flatness, sharp edge and curve suitability. In some examples, a monolithic or single layer belt can be used, while in many examples the belt will have multiple layers.

[0094] Conveyor belts are used for a variety of applications to support and move objects or materials between points. Depending on the intended application, conveyor belts can have custom configurations on their underside (e.g. tracking guides), their upper side (e.g. flights) and / or at their lateral edges (e.g. side walls). The present invention can accommodate any and all such modifications to flat belts, provided that the belt ends need to be joined to form a closed loop for their intended use. The present invention relates to a method of forming a belt joint, a reinforcing material for the joint and the resulting belt joint.

[0095] The present invention is initially described with respect to the drawings of a belt having two or more layers.

[0096] A method for joining opposite end edges of a belt together is now described.

[0097] In a first embodiment of the invention, referring to Figure 1 , the joint 100 comprises a first end edge 20 and a second end edge 30 of the belt 10 joined to a reinforcing fibre section 40. The first and second ends of the belt define an interface at the region where they join (e.g. overlap). This interface can be described as a seam between the end edges 20, 30.

[0098] The fibre section 40 comprises a body portion 41 which is composed of woven para-aramid fibres which can resist high tensile loads, are tear resistant and have excellent fatigue properties when compared to other regions of the belt. The properties of para-aramid fibres make them an ideal choice for reinforcing the joint. They have a tensile strength which is five times greater than steel (when comparing weight for weight). They are also lightweight and highly flexible which is important for endless belts as they are wound around rollers and flexed. Para-aramid also has good fatigue properties, particularly resistance to flexing, which is also important as the load on the joint is subject to changes as it passes around the conveyor. Para-aramid is also tear resistant which means that a tear / cut in the joint is less likely to propagate. Furthermore, para-aramid can be woven and designed into many different weaves or other fabric patterns.

[0099] The body portion is coated with an adhesive which is configured to connect the body portion 41 to the belt (e.g. the composition of the adhesive is selected based on the materials of the belt and the fibre section). When the belt is a conveyor belt made from PVC or PU, a suitable adhesive is a rubber cement such as Rima Tiptop C4 cement (RTM); however, the specific adhesive used will depend on both the type of fibre on the fibre section and the material of the belt.

[0100] Different adhesives for bonding the fibres of the fibre section to the belt material have been considered. The adhesive can include one or more of polyvinyl acetate (PVA), polyvinyl alcohol (PVOH), polyacrylate, polyester acrylate, acrylic solvent cement or rubber cement such as Rima Tiptop C4 cement (RTM). Where the fibres include aramid, the adhesive can be any material capable of bonding / engaging / attaching aramid to the belt material. It will be appreciated that the skilled person can routinely experiment with different adhesives depending on the particular fibre material or fibre blend selected and the belt material.

[0101] To manufacture the fibre section, the body portion comprises an arrangement of woven and / or non-woven fibres which are first coated / treated in the adhesive. In this regard, fibres such as aramid fibres are difficult to cut / treat when in the untreated loom state.

[0102] The adhesive is dried, hardened or cured by methods known to those skilled in the art, for example UV curing, heating or allowing to stand under ambient conditions.

[0103] The fibre section can be treated / coated on the surface with a non-stick coating such as Teflon (RTM) to prevent the adhesive from sticking to the surface on which the fibre section is being worked.

[0104] The adhesive makes the fibre section easier to work with, for example to cut and position in place within / on the belt. The adhesive keeps the fibres properly aligned and helps to prevent the fibres from bunching up, making it easier to cut. The fibre section, including the body portion and cured adhesive, can be cut, for example to form a plurality of fibre sections 40 from a larger fibre section, or to cut / shape the edges to fit with a particular belt profile.

[0105] The fibre section 40 is generally quadrilateral / rectangular, having opposite first and second edges 42, 43 separated by side edges 44. The first and second edges correspond to the width of the belt 10. The length of the side edges 44 corresponds to the extent of the interface between the belt end edges 20, 30.

[0106] The fibre section 40 is coated with adhesive to ensure that all areas of the fibre fabric are fully covered / saturated with adhesive. In the prototype application, the fibre section is coated by hand using a brush. The non-stick support surface ensures that the adhesive is deflected from the surface back onto the body portion and prevents the adhesive containing the fibre section from sticking to the surface. In practical applications of the technique for producing the fibre section, a different coating method would typically be used, such as roller coating, dip coating, spray coating etc. In particular, it is envisaged that a coating process in which the fabric of the fibre section is passed around a roller submerged in a tank of adhesive is used, such that the fibre section picks up adhesive as it passes around the roller. Various industrial fabric coating processes can be considered to produce the desired composite fibre section material.

[0107] The adhesive is allowed to dry / cure in the ambient environment, such that it hardens, making it easier to handle and work with. Once dry, the fibre section 40 can be cut to size, for example cut into strips. The desired shape can be determined by the dimensions of the belt 10.

[0108] In Figure 1 the fibre section 40 is rectangular in shape, with the longest width edges 42, 43 corresponding to the width of the belt; however, the width of the fibre section can be slightly shorter, such that it does not protrude from the side edges 1 1 of the belt 10.

[0109] The fibre section 40 can be produced in batches or continuously to reduce production time and increase scalability. In this case, multiple fibre sections 40 can be cut from a larger / longer section of material.

[0110] Figure 1 a to e illustrate a first embodiment of the present application. The figures illustrate various stages of joining a belt 10 to a reinforced fibre section 40 to form a belt loop. Part (a) shows the first end edge 20 and second end edge 30 of the belt 10 and the fibre section 40. The belt 10 comprises a belt body extending in a longitudinal direction L.

[0111] The middle section 50 of the belt 10 separates the first end edge 20 and the second end edge 30. Only a portion of the middle section 50 is shown and in fact the middle section would loop around between the first end edge 20 and the second end edge 30, such that those end edges are joined by a continuous belt body.

[0112] The belt body 10 comprises layers that are bonded together. Although there can be multiple layers, the illustrated embodiment contains only two layers. The belt can comprise any of conventional PVC, PU or silicone belts, for example.

[0113] In part (b), the layers of the belt 10 are separated along the first end edge 20 up to the intermediate section 50 to define a top layer 21 and a bottom layer 22. The intermediate section 50 can be defined as the region in which the layers / plies are not separated. A line 51 has been provided as a reference to show where the transition between the intermediate section 50 and the first end edge 20 occurs.

[0114] When separating the layers 21, 22, a knife or similar sharp tool can initially be inserted into or along the end edge 20 to separate the plies. The layers 21, 22 can then be pulled / pried apart in the longitudinal direction L up to the desired separation length. This can be achieved in conjunction with pressure / agitation of the knife. In some examples, a wire or similar can be used in place of a knife / blade.

[0115] The second end edge 30 is split in a similar manner. This embodiment allows for splitting or separating the belt at the interface between the existing layers. In examples where the belt is a monolithic structure rather than a layered structure, the monolithic structure can be cut into at a predetermined height to create separate end sections for the purposes of the present invention. Thus, this can create a similar arrangement of partial layers as shown in part (b) above. Figure 1

[0116] In part (c), the fingers 23 are punched into the top and bottom plies 21, 22 by methods known to those skilled in the art. The fingers 23 are generally wedge shaped, each finger being triangular and extending from a base to a distal point or apex. The fingers 23 can extend partially in the first end edge 20, such that there is a gap between the base of the fingers 23 and the transition line between the intermediate section 50 and the first end edge 20. Alternatively, the splice cut can extend fully up to the transition line 51.

[0117] The position of the splice cut can be different from the position on the top and bottom surfaces 21, 22, such that the fingers 23 extend at different lengths. For example, the fingers 23 on the bottom ply 22 can extend further than the fingers of the top 23, or vice versa. The splice can be configured to cut the first end edge 20 such that when bonded to the fibre section 40, the edge lies completely above the body portion 41, i.e. the edge does not protrude above the first edge 42 of the body portion 41. However, in some embodiments, a portion of the cut can extend above the first edge 41.

[0118] As shown in part (d), the hole punching / cutting process is repeated for the second end edge 30 from the opposite side so as to extend over the second edge 43 of the fibre section 40.

[0119] Alternatively, the splice cut can be punched into both end edges simultaneously.

[0120] ​Figure 1 Only one example of a construction for splicing together the opposite end edges of the belt 10 is shown. It will be appreciated that the ends can be free of such a construction, and the end edges 20, 30 can simply abut one another to form the joint. Alternative splicing constructions can also be used as desired.

[0121] After the layers 21, 22 are separated, it is generally desirable to cut the construction / finger 23. This makes the layer separation process simpler to implement. Also, in this way, individual layers can be cut / stamped individually if desired to provide different or offset constructions. Alternatively, the layers can be held together and cut collectively. If desired, the two ends can be held together and cut with ordinary tools.

[0122] The fiber section 40 is located between the top ply 21 and the bottom ply 22, with or without the formation of a construction 23.

[0123] The separated layers of the first end edge 20 of the belt are located over the opposite major surfaces of the fiber section 40 (i.e., over and under the fiber section). The separated layers of the second end edge 30 are then positioned over the fiber section in the same manner as the first end edge but from the opposite direction. The fingers of the first end edge and the second end edge are located over the fiber section in an alternating or interdigitated manner such that when joined, the first end edge fingers are joined between the second end edge fingers, and vice versa. This forms a joint ready for joining. Figure 1 Z-shaped splice arrangement of (e).

[0124] In addition to the adhesive coating of the fiber section 40, additional adhesive can be applied at the interface / joint between the opposite end edges to bond them together along with the bond formed with the fiber section 40.

[0125] In some examples, there can be multiple fiber sections, with the fiber sections inserted between different layers of the belt ends to define a stack of fiber sections. In this way, more than one fiber section can be used in order to increase the reinforcement of the joint. The uppermost layer defines the first major surface of the belt in use and can cover the fiber section (i.e., the first major surface of the fiber section). The lowermost layer defines the second major surface of the belt in use and can cover the fiber section (i.e., the second major surface of the fiber section).

[0126] Figure 1(e) shows the joint during / after processing. Heat and pressure are applied to melt the adhesive of the fibre section and cause it to bond / fuse to the belt material, such as the PVC / PU material of the belt body. For this a heated press can be used. It has been found that processing temperatures in the range of 120-200 °C are practical. Depending on the material combination used, applied pressures between 0.1 - 10 bar are also dragged along and found to be practical. The pressure is desirably applied evenly over the joint area.

[0127] The duration of the heat / pressure processing to form the desired joint can be up to 10 minutes. However, it has been found that elevated temperatures and pressures for various adhesives, fibres and belt materials can be much lower, for example less than 1 minute, while still providing a properly bonded joint. Also, the skilled person will appreciate that the materials used, the thickness of the belt, the number of layers and / or the number of reinforcing sections can all influence the optimal pressure settings and associated duration.

[0128] An interface is formed where the first end edge abuts, joins or is immediately adjacent to the second end edge. This interface can look like a seam on the finished product.

[0129] The fibre section is discontinuous, such that it extends only partially into the belt body, i.e. in the direction of the longitudinal axis L into both the first and second end edges. Preferably, the fibre section extends over the longitudinal length of the interface. This ensures that the layers of the opposite end portions 20, 30 are fully supported to, for example, the end of the interface, such as the tip of the splice construction 23, which can represent a regular weak point in the belt joint. The fibre section extends only over a predetermined length in the longitudinal direction beyond the extent of the interface, such as 10 cm, 5 cm, 3 cm or less. On both sides of the interface, for example in the upstream and downstream directions relative to the longitudinal direction of travel of the belt in use, the extent of the fibre section can be equal.

[0130] The interface can be entirely contained within the footprint or planar area of the fibre section.

[0131] The first and second end edges can be part of the same belt body, wherein the belt body is curved / folded so as to form an endless belt. Such a belt will thus have a single reinforced joint. Alternatively, the first and second end edges can be part of two adjacent belt bodies to be joined. In this way, a belt of any desired length can be achieved by bonding multiple belt bodies together. The belt will then have multiple reinforced joints at different points along the total length of the belt.

[0132] Figure 2A schematic cross-sectional side view of the reinforced joint 100 is shown. The top and bottom layers / top and bottom plies extend above and below the fibre segments 40 and are joined to the fibre segments. The interface 12 is defined where the first and second end edges meet or overlap. The seam is visible when viewing the belt from above and below.

[0133] Figure 3 (a) shows a schematic view of a first embodiment in which the fibre segments have been made visible by the formed belt joint / interface 12. It can be seen that the seam of the interface 12 lies approximately above the major surface of the fibre segments 40. In this example, the axis of the interface 12 is perpendicular to the longitudinal axis L and the path followed zigzags back and forth around the interface axis Z.

[0134] The direction of the fibres in the fibre segments 40 is shown schematically as similar to a mesh or grid, with the warp and weft yarns arranged perpendicular to the longitudinal axis L and horizontally. The alignment of the fibres in the fibre fabric mat is therefore obliquely offset from the path of the interface 12. The alignment of the fibres relative to the longitudinal axis L can be used to prevent any yielding in the fibre segments 40 in the direction of applied tension in use. That is, the fibre segments are inextensible in the longitudinal direction L.

[0135] In various other examples, the interface axis and alignment of the fibres in the fibre segments can be varied independently or collectively relative to the longitudinal axis L. In Figure 3 The interface axis 48 is shown in (b) to be obliquely angled relative to the longitudinal axis of the belt. In this example, the fibre segments 40 can be rectangular or can be in the form of a parallelogram to follow the direction of the interface axis 48. The lateral edges of the fibre segments 40 can therefore also be obliquely angled relative to the longitudinal axis.

[0136] Also in Figure 3 In (b), the angle of the warp and weft yarns of the fibre segments 40 is offset from the longitudinal axis, for example by 45 degrees.

[0137] Figure 4 An alternative embodiment of the invention is shown in which the first and second end edges of the belt comprise a plurality of separate plies of layers and fibre segments inserted between each ply. Once processed, the stack of fibre segments produces a robust joint which is better able to resist high tensile loads.

[0138] In other examples, the fibre segments 40 can be placed over the outer surface of the belt 10 (i.e. on the upper surface and / or underside of the belt) to cover the interface 12 or associated seam. Such an arrangement can be used in addition to individual internal fibre segments 40 between the layers of the belt, or in addition to a stack of fibre segments.

[0139] In some examples, a fiber segment on the outer surface of the belt can be used in place of the fiber segments 40 between the layers. This can be particularly useful, for example, when repairing an existing belt by reinforcing an existing interface. In such examples, the fiber segments 40 can be provided with one or more outer plies so as to comprise a ply-like composite structure. The one or more outer plies can provide a cover ply to the fiber segment to fuse to the surface of the belt when the cover ply is attached in place to the belt or cover the fiber ply. Any of the features discussed herein with respect to the alignment of the fiber segments relative to the interface can also apply to the fiber segments applied to the outer surface of the belt. A pair of outer fiber segments can sandwich the belt (i.e., the belt interface region) in between.

[0140] Various options for additional embodiments

[0141] Figure 5 a-b show additional embodiments of the invention. Both the first end edge and the second end edge are joined to a separate fiber segment 40. The fiber segment 40 can be adhered between the layers of the belt end or to the outside of the belt as described above. The edges of the first edge-to-edge and the second edge-to-edge are approximately aligned with the edges of the fiber segment. In this embodiment, the fiber segment covers the first end and the second end and is joined using the methods described above.

[0142] As Figure 5 As shown in b, the fiber segment and the belt (i.e., edge-to-edge) include a plurality of apertures 51 that allow for the insertion of mechanical fasteners 50 such that the first end edge 20 can be coupled to the second end edge 30. In the embodiment shown, the fasteners 50 are nails or eyes / rings. However, any conventional mechanical fastener capable of coupling the end edges together can be used instead, such as a lacing or hinged clip through the eyelets 51.

[0143] The apertures include eyelet rings 51 to provide some rigidity to the apertures and prevent fraying.

[0144] While four fasteners 50 are shown in the figures, any number of fasteners can be present, i.e., typically greater than 4. Thus, when mechanical fasteners are used at the interface rather than at a bonded / spliced interface, the invention can be used to provide reinforcement. In this example, the interface 12 is wider than the seam of a spliced interface. In some examples, the fiber segment 40 can be continuous across the interface 12, i.e., continuous between the mechanical fasteners 50. In such examples, the fiber segment 40 can have a cover ply as described above.

[0145] The belt can comprise a plurality of eyelets, the plurality of eyelets can be aligned along the width of the belt (i.e. aligned parallel to the width edges). The coupling means can further comprise a mechanical fastener coupling the first end portion to the second end portion. The fastener can be a clip, a pin or a tie. The fastener can be selectively removable such that it can be replaced in the event of damage.

[0146] The method for mechanical joint reinforcement can be used for other belt types (i.e. timing belts and monolithic / homogeneous belts).

[0147] The location of the interface 12 can be formed differently on the first major surface of the belt (i.e. the top surface in use) compared to the second major surface of the belt (i.e. the bottom surface in use). For example, the first end edge and the second end edge can have bevelled edges for complementary coupling, i.e. a ramp / diagonal joint through the thickness of the material. If the first end edge and the second end edge have been spliced, the length and / or width of the fingers on the top surface can be different to the fingers on the bottom surface. For example, the first end portion can be composed of several layers, with the spliced fingers on the top layer sheet being longer than the spliced fingers on the bottom layer sheet. Alternatively, the spliced fingers of the first major surface and the second major surface can have the same length.

[0148] The fibre section (e.g. the body portion thereof) can extend from the interface a maximum distance of 100 cm in the direction of the first end edge and / or the second end edge. The maximum distance can be less than 50 cm or 25 cm, 20 cm, 15 cm, 10 cm or 5 cm. The maximum distance depends on the shape and location of the interface. In the case where the joint comprises spliced fingers, the interface will be zig-zag shaped. The maximum distance can be defined between the tip / vertex of the finger to the edge of the fibre section. The maximum distance can alternatively be defined as the distance from the free edge of the separated layer (e.g. the edge of the end edge) on a given end edge to the unseparated intermediate section.

[0149] The spliced fingers / constructs can be shapes other than triangular, for example, they can be serrated, such as to have a toothed appearance. The fingers can be elongate such that they are configured to extend or elongate in the longitudinal axis / direction of the belt compared to their width. Each end edge can comprise four, five, six or more spliced constructs / fingers.

[0150] The invention can accommodate other types of joint, such as a wedge splice.

[0151] Test results

[0152] Embodiments of the invention have been subjected to tensile testing and puncture testing to determine the relative strength of the reinforced interface.

[0153] Rectangular belt sections including reinforced junctions were prepared according to various different belt thicknesses and combinations of belt, adhesive, and fiber segment material. The belt sections were attached to the grips of a tensile testing machine and stretched at a constant rate of 100 mm / min until they broke.

[0154] It was found that the reinforcement of the splice resulted in an improvement in tensile strength between 13% and 84% relative to conventionally spliced belts in terms of maximum force (N) and tensile strength (N / mm).

[0155] Mechanical joints using a similar line hook as the embodiments described herein were also tested and showed an improvement in tensile strength of approximately 11% when compared to conventional line hook splicing techniques. However, this relatively small improvement can be attributed to the nature of the splice failure, which was observed to be caused primarily by the line hook opening apart rather than the belt breaking.

[0156] For the puncture strength test, a cylindrical flat punch with an 8 mm diameter was employed. The load was applied at the midpoint of the center finger of the splice at a constant rate of 5 mm / min until the splice failed. Puncture tests were performed on samples spliced with heat pressing using the splice adhesive and the maximum force (N) and compressive stress (MPa) results were recorded.

[0157] Overall, it was observed that the reinforcement of the splice resulted in a significant reinforcement of the load that the belt could withstand before failing. The resulting splices were up to 4.8 times stronger than samples using conventional splicing techniques. Some of the reinforced splices were even stronger than the standard unspliced belt sample (i.e., the body portion of the belt that does not include the joint). In particular, the strongest reinforced splice according to the present invention tested exhibited a maximum force and compressive stress value that was 64% higher than the maximum force and compressive stress values of the unspliced body portion of the belt.

[0158] The fact that the reinforced joint can provide greater resistance to puncture than the rest of the belt is a previously unexplored discovery in the art and is particularly encouraging. In short, if the joint can be reinforced to become the strongest portion of the belt, this greatly reduces the likelihood of joint failure and increases the operational life expectancy of the belt. This means that the belt will be more likely to wear out to achieve its maximum operational life rather than experience an earlier belt failure.

[0159] It is envisaged that the present invention will be used primarily to address the largest source of belt waste, i.e., PVC (used in PVC and rubber belts). However, the present invention can be used for thinner types of belts, i.e., PU, polyolefin, cotton, polyester, polyamide, and silicone belts.

Claims

1. A method for forming a joint in a belt, the belt having a first end edge and a second end edge to be joined, the method comprising: A fiber segment having a first edge and a second edge is provided, the fiber segment comprising aramid fibers; The first end edge of the belt is arranged to at least partially overlap with the first edge of the fiber segment. The second end edge of the belt is arranged to at least partially overlap with the second edge of the fiber segment; as well as In the arrangement, the first end edge and the second end edge are joined to the fiber segment to form a joint interface between the first end edge and the second end edge, wherein the joint interface is reinforced by the aramid fiber.

2. The method of forming a joint of claim 1, wherein, The fiber segment includes a first main surface, wherein the first end edge is joined to the first main surface.

3. The method of forming a joint of claim 1 or 2, wherein, The second end edge is joined to the first main surface.

4. The method of forming a joint of claim 2 or 3, wherein, The fiber segment includes a second main surface, wherein the first end edge is also connected to the second main surface.

5. The method for forming a joint according to claim 4, wherein, The second end edge of the belt is also engaged with the second main surface.

6. The method for forming a joint according to any one of the preceding claims, wherein, The belt includes multiple layers, wherein the fiber segments are inserted or arranged between the layers at the first end edge of the belt.

7. The method for forming a joint according to claim 6, wherein, The fiber segment is inserted between layers at the second end edge of the belt.

8. The method of forming a joint according to claim 6 or 7, wherein, The layer is separated before the fiber segment is inserted, for example, by separating the layer from the first end edge and / or the second end edge to a predetermined longitudinal distance.

9. The method of forming a joint according to any one of the preceding claims, wherein, The first end edge and / or the second end edge are shaped to define a joint structure.

10. The method for forming a joint according to claim 9, wherein, The splicing section includes finger-shaped parts with a length of 50 mm-150 mm or 90 mm-100 mm.

11. The method of forming a joint according to any one of the preceding claims, wherein, The splicing portion structure of the first end edge is located between the opposite splicing portion structures of the second end edge.

12. The method of forming a joint according to any one of the preceding claims, wherein, The first end edge is adjacent to or overlaps with the second end edge when it is joined to the body portion.

13. The method of forming a joint according to any one of the preceding claims, wherein, The fiber segment includes a fiber body portion coated with an adhesive.

14. The method of forming a joint according to claim 13, wherein, Once positioned on the belt, the fiber segments are processed to melt the adhesive, thereby bonding the first end edge and the second end edge to the body portion.

15. The method of forming a joint according to claim 13 or 14, wherein, The fiber segment is cut from the larger fiber segment.

16. The method of forming a joint according to any one of claims 13 to 15, wherein, The fiber body portion includes woven fibers.

17. The method of forming a joint according to any of the preceding claims, wherein, The fiber segment includes para-aramid fibers.

18. The method of forming a joint according to any one of the preceding claims, wherein, Fasteners are engaged to the first end edge and the second end edge, the fasteners preferably being hook fasteners, clips, or nails, and the fasteners span the joint interface.

19. A reinforced belt, comprising a belt body and fiber segments, wherein, The fiber segment includes aramid fibers, and the fiber segment is joined to a first end edge of the belt body, the first end edge forming an interface with a second end edge of the belt body, such that the belt body defines a closed loop, the fiber segment has a discrete length in the longitudinal direction of the belt body, such that the fiber segment terminates on either side of the interface, and the belt body extends beyond the fiber segment in the longitudinal direction.

20. The reinforced belt according to claim 19, wherein, The belt is a transmission belt or a timing belt.

21. The reinforced belt according to claim 19 or 20, wherein, The belt body includes multiple locally fiber-reinforced joints located at longitudinally spaced intervals.

22. The reinforced belt according to claims 19 to 21, wherein, The belt comprises multiple layers, and the fiber segments are located between adjacent layers.

23. The belt according to claims 18 to 21, wherein, The belt is made of polyvinyl chloride (PVC) or polyurethane (PU).

24. The belt according to claims 18 to 21, wherein, The fiber segment comprises woven para-aramid fibers.

25. A fiber segment sheet for forming a reinforced belt joint, the fiber segment having a fiber composite layer comprising a fabric having aramid fibers disposed in an adhesive matrix; wherein, The adhesive at least partially covers the aramid fibers and is cured or hardened to allow processing of the fiber segments.

26. The fiber segment according to claim 25, wherein, The fiber is a raw, loom-state fiber within the adhesive matrix, such as an uncoated fiber.

27. The fiber segment according to claim 25 or 26, wherein the adhesive is recyclable, and optionally the adhesive comprises a thermoplastic.

28. The fiber segment according to any one of claims 25 to 27, wherein the adhesive comprises a rubber adhesive.

29. The fiber segment according to any one of claims 25 to 28, wherein, The fibers are woven.

30. The fiber segment according to any one of claims 25 to 29, wherein the fabric has an opening therein, and a keying position is provided in the opening for penetration by belt material in use.

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