Insert element, roller system and method for producing an insert element

Abstract

An insert element (1), in particular for guiding a rope or cable, in particular for a cable car system, is provided. The insert element (1) comprises: a primary layer (2) and a secondary layer (3) which is provided in and / or on the primary layer (2). The insert element (1) has a first insert element side (4) which is designed to enter into contact with an element (8) to be guided in a guiding direction, in particular in a circumferential direction, in particular a rope or cable, 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 respect of at least one material property. The insert element (1) has a substantially uniform cross section along the guiding direction. The insert element (1) extends in cross section in a radial direction (R) and a width direction (B) which are each orthogonal to the guiding direction and to each other. A roller system (100) and a method for producing an insert element are also provided.

Description

[0001] Insert element, roller system and method for producing an insert element

[0002] The present invention relates to an insert element, in particular for guiding a rope or cable, in particular for a cable car system, a roller system, in particular for guiding a rope or cable, in particular for a cable car system, and a method for producing an insert element, in particular for guiding a rope or cable, in particular for a cable car system.

[0003] Insert elements or insert linings are used to guide, deflect, and drive circulating ropes, or wherever loads are guided on tracks or rails. Such insert elements can be designed as closed or open rings, segments, or cords (longitudinal profiles). Typically, one or more profiles (i.e., geometric shapes) can be incorporated on the side facing the rope or track / rail guide, with a geometry corresponding to the rope, track, or rail.

[0004] Known insert elements typically comprise an outer layer that comes into contact with a cable to be guided, and a reinforced inner layer that ensures the insert element sits securely on a rim or the like. Furthermore, insert elements are also known that can be clamped to a roller or the like via its flanks. In particular, with this type of insert element, no reinforced inner layer is necessary, so the insert elements consist only of a single outer layer. The outer and inner layers of the known insert elements are usually designed for long service life. This ensures a sufficient service life of the insert element.

[0005] However, these designs, specifically those designed for long service life, pose problems in that they make it difficult or even impossible to achieve other desired properties of the insert element. Particularly due to the ever-expanding application areas of such insert elements, for example, in urban cable car systems, increasingly stringent requirements are being placed on insert elements, such as vibration prevention, noise reduction, high conductivity, vibration-damping properties, and / or braking properties.

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

[0007] The above object is achieved with an insert element having the feature of claim 1, with a wheel system having the feature of claim 29 and with a method for producing the insert element having the feature of claim 30.

[0008] According to one aspect of the present invention, an insert element is provided, in particular for guiding a rope or cable, in particular for a cable car system. The insert element can have a primary layer and a secondary layer provided in and / or on the primary layer. The insert element can have a first insert element side, which is designed to come into contact with an element to be guided in a guide direction, in particular in a circumferential direction, in particular a rope or cable, and a second insert element side opposite the first insert element side. The primary layer and the secondary layer can differ with regard to at least one material property. The insert element can have a substantially constant cross-section along the guide direction.The insert element may extend in the cross section of a radial direction and a width direction, wherein the radial direction and the width direction are each orthogonal to the guide direction.

[0009] In the cable car rings known from the prior art (e.g. insert elements), a compromise is made between dynamic and mechanical behavior when it comes to the material. In contrast, according to one aspect of the present invention, the insert element has different layers (e.g. material layers) in order to improve both wear resistance and dynamic behavior. This leads on the one hand to a longer service life of the insert element and on the other hand enables new areas of application for highly stressed applications. In other words, a multi-layer composite system can be provided as an insert lining (i.e. insert element) for guiding, deflecting and driving circulating cables. The insert element can be a closed or open ring. Furthermore, the insert element can also be designed as an insert cord. The insert element can be secured in an insert on a wheel or rim.Furthermore, the insert element can be provided, in particular clamped, between two flanged wheels. The insert element can be a separate part and designed to be secured to a roller. The roller, in turn, can be rotatably held, for example, on a structure such as a support. For example, the roller can be rotatably mounted on the structure by means of a plain bearing or roller bearing. A rope or cable can be placed on the insert element and supported and / or guided thereby. A guide direction (for example, a rope guide direction) can designate the direction of extension of the rope to be guided. The insert element can also be designed to support the rope against transverse displacement transversely to the guide direction. The insert element can have a lower strength than the roller to which the insert element is secured.In other words, the insert element can be formed from an elastic material that at least partially surrounds the rope to be guided. To improve guidance properties, the insert element can at least partially adapt 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 components to prevent direct contact between a rope or cable and the component. It is also conceivable for the insert element to be designed as an insert cord that can be laid or wound around guide components. These guide components can, for example, be wheels or disks that serve to drive or deflect a rope. In such a case, the linings are typically connected to the wheels or disks by clamping or screwing.Furthermore, the insert element can be designed not only to guide a rope or cable, but also to come into contact with a rail or the like in order to be guided on the rail. For example, an insert element can serve as a wheel tire that can be attached to a wheel body. The primary layer and the secondary layer can each be a volume layer that extends in all three spatial directions. The secondary layer can be arranged completely or partially within the primary layer. Furthermore, the secondary layer can be arranged on a surface of the primary layer. The insert element formed from the primary layer and the secondary layer can have a first insert element side and a second insert element side. A layer in the sense of the present invention can be a flat layer that has a defined and determinable extent.This means that particles, composite materials or the like which are added to the casting compound, for example, during casting of the insert element cannot be regarded as a layer. In particular, such additives form a random, indeterminate arrangement and are not meant to be a layer within the meaning of the invention. The first insert element side can be oriented substantially parallel to the second insert element side. The first insert element side can be the side of the insert element which comes into contact with the cable or the rail when the insert element is in use. The second insert element side can come into contact with a rim, tire or other object on which the insert element is provided. The first insert element side and the second insert element side can be the sides of the insert element with the largest area.The sides of the insert element can be defined by edges of the insert element. The guide direction can be the direction in which a rope, cable, or rail passes through the insert element during use of the insert element. The primary layer and the secondary layer can be layers made of different materials. This can be characterized, for example, by both layers having at least one different material property. This can provide an insert element with at least two layers, wherein the layers differ. This can provide a combination of desired properties of the insert element in order to achieve an overall more widely applicable insert element.Thus, an insert element can be provided as a multi-layer insert element with a hybrid structure, wherein the primary layer and the secondary layer can be arranged at different positions and in different combinations within the cross-section of the insert element. The cross-section of the insert element can be a cross-section in the main extension direction of the insert element. Furthermore, the cross-section can extend along the guide direction of the insert element. In the case where the insert element is designed as an annular element, the guide direction can run in the circumferential direction. In other words, a cable guided through the insert element can be guided tangentially along the insert element or can be guided through it.A constant cross-section can mean that the cross-section does not change in its spatial extent by more than 10% along the guide direction or extension direction of the insert element. In other words, a distribution or arrangement of the primary layer and the secondary layer in the cross-section of the insert element can also remain constant. If the insert element is cut at different positions along the guide direction, the layers can always be arranged essentially constantly (i.e. identically). In other words, this does not mean a random distribution of the layers in the cross-section. Viewed in the cross-section of the insert element (i.e. when viewed two-dimensionally), one extension direction can be defined as a width direction and another extension direction, which runs at a 90° angle to the width direction, as a radial direction.In other words, the width direction can run along the first insert element side and / or along the second insert element side. The radial direction or vertical direction can be a direction directed away from the first insert element side. By using different layers in the composite of the insert element, undesirable compromises in material development can be avoided, and by optimizing the position and dimensions of the respective layers, an insert element with a variety of properties can be provided. For example, an insert element can be created with a dynamically optimized inner layer and a mechanically and / or wear-optimized outer layer. Furthermore, a conductivity adjustment of the outer layer and / or the inner layer (for example, for signal transmission or potential equalization) can be realized.A sound- or vibration-damping outer layer and / or inner layer can be implemented. Additionally or alternatively, the friction and braking properties of the insert element can be optimized. Furthermore, the weather resistance of the outer layer can be optimized. Furthermore, the insert element can be provided with the option of retreading the insert element and / or using recycled raw materials, thus improving its recyclability.

[0010] Preferably, the primary layer and the secondary layer are each formed as an elastomer layer or polymer layer. By using an elastomer, both the dynamic properties and the wear properties of the insert element can be optimally adjusted. For example, a mixture of different polymers can be provided for this adjustment. Furthermore, at least one filler can be added to the polymer in order to adjust certain properties of the polymer. Carbon black and / or silica, for example, can be used as fillers. In addition to the internationally valid ASTM classification for carbon blacks, carbon black can also be divided into highly active, active, semi-active, and low-active carbon blacks. Highly active carbon blacks can have a large surface area, while low-activity carbon blacks can have a small surface area. By using carbon black as a filler, the conductivity of the layer can be adjusted.Furthermore, wear resistance can be increased by using highly active carbon black. In contrast, dynamic behavior (heat build-up) can be improved by using low-activity carbon black compared to highly active carbon black. Heat build-up can be determined using the Goodrich test (DIN 53533, ASTM D 623, ISO 4666 / 3, 4666 / 4, BS 903 part A50 or J IS K 6265). Heat build-up can be understood in the broadest sense as how much heat builds up in a material, for example through flexion, under dynamic loading. Favorable dynamic behavior can prevent excessive heat build-up within the material. This can counteract thermal failure of the material. Furthermore, a polymer or elastomer each exhibits improved vibration and sound dampening, for example compared to Becorit. Furthermore, polymers or elastomers have a low coefficient of friction.The secondary layer is preferably a wear-resistant layer. A wear-resistant layer can have special mechanical properties in order to keep wear as low as possible. For example, the secondary layer can be provided on the first insert element side and thus be designed to come into direct contact with the rope, cable or rail and, in the event of such contact, reduce wear on the secondary layer due to its wear resistance. In contrast, the primary layer can be geared to other properties so that an advantageous insert element can be provided overall. The secondary layer is preferably arranged at least in sections on the first insert element side. For example, the secondary layer can only be provided in sections (i.e. exclusively in sections) in the cross-section of the insert element.This can result in an insert element in which both the primary layer and the secondary layer are present on the surface of the insert element on the first side of the insert element. The secondary layer can, for example, be designed to exhibit particularly low wear upon contact with a rope, cable, or rail. The primary layer can, for example, have vibration-damping, conductive, and sound-damping material properties to ensure properties other than wear resistance of the insert element. Thus, an insert element can be provided that can be used in many applications.

[0011] Preferably, the at least one material property comprises wear resistance, heat build-up, conductivity, sound dampening, vibration dampening, a coefficient of friction, weather resistance and / or thermal conductivity. Wear resistance can be characterized by low abrasion during operation of the insert element. Furthermore, wear resistance can be achieved through high strength and / or high tear resistance. This allows the insert element to be particularly durable and to remain in use for a long time. Heat build-up, or heat build-up test, can be determined according to the Goodrich test (DIN 53533, ASTM D 623, ISO 4666 / 3, 4666 / 4, BS 903 part A50 or J IS K 6265). Heat build-up can be understood in the broadest sense as how much heat builds up in a material, for example through flexion, under dynamic load.An insert element can be described as conductive if the specific electrical resistance is <10. 4 Ohm x cm. For a single-layer element with a specific electrical resistance of >10 4 Ohm x cm to <10 6 Ohm x cm can be considered an antistatic insert element. An insert element with a specific electrical resistance of >10 6 Ohm x cm and < 10 8 Ohm x cm can be considered an electrically neutral insert element. For an insert element with a specific electrical resistance of >10 8Q x cm can be referred to as an insulating insert element. Thus, the insert element can be adapted to specific areas of application (e.g. signal transmission, potential equalization and the like). For example, it is possible to make an outer layer (e.g. the primary layer) conductive or insulating by using the insert element with at least two different layers. The inner layer (e.g. the secondary layer) can then, for example, determine a dynamic behavior of the insert element. In this case, a current flow can be transmitted, for example, via a cable via the insert element to a flanged disk with which the insert element is in contact. Furthermore, by only providing a conductive layer in sections (e.g.A single-layer element can be provided as a multi-component system (the primary layer or the secondary layer), providing a mechanically optimized and conductive material without resulting in a conductive overall system. Conductivity can be achieved, for example, by adding carbon black to one of the layers.

[0012] Sound damping and / or vibration damping may be particularly required for cable car systems in urban use. This can lead to a reduction in noise emissions. In the prior art, this problem is currently solved by using a material in the insert element that is optimized with regard to noise emission properties, which, however, has a detrimental effect on the expected service life of the insert element. The insert element according to the present embodiment provides a multi-layer composite system that imposes the expected disadvantages of a noise emission-reducing layer on the overall system (i.e.The noise reduction properties can be optimized and varied by varying the layer thickness in the radial direction. This allows the insert element to be adapted to the respective location and intended use. Dynamically optimized can mean that the heat build-up is as low as possible while maintaining wear resistance.

[0013] According to Ö-Norm 12385-8, Section A.2.1 "Coefficient of Friction," the coefficient of friction can be met for insert elements under defined operating conditions (e.g., dry or greased). Since only an externally arranged layer influences the coefficient of friction of an insert element, the overall system can be optimized by adding an additional layer not located on the surface of the insert element. For example, the primary layer can have a required coefficient of friction and be located on the first side of the insert element, while the secondary layer can ensure the necessary dynamic resistance of the insert element. This makes it possible to achieve an overall system that meets the requirement regarding the coefficient of friction, but is also optimized with regard to other properties (e.g., dynamic properties or vibration-damping properties).The dynamic resistance can be indicative of longevity under dynamic load.

[0014] Furthermore, the layer (either primary layer or secondary layer) provided on the first insert element side can comprise at least one material property such as weather resistance. When it comes to weather resistance, the focus is also on that layer of the insert element which faces the environment (i.e. the outside world). Thus, for example, the primary layer, if arranged on the first insert element side, can be designed to be particularly weather-resistant. The secondary layer, which is arranged further inwards in the radial direction or vertical direction, can, in contrast, ensure other properties of the insert element, such as dynamic resistance. In view of climatic changes and the expansion of the areas of application, the insert element can thus be directly exposed to the weather and, at the same time, the longevity of the insert element can be optimized.

[0015] Thermal conductivity can describe how quickly heat can be dissipated from the interior of the insert element. For example, deformation of the insert element and the resulting flexion can generate heat inside the insert element. If this heat is not dissipated, thermal failure due to carbonization can occur. If a layer (e.g. secondary layer and / or primary layer) is designed so that it has increased thermal conductivity, the heat generated can be easily dissipated from the interior of the insert element. This can prevent thermal failure of the insert element. Furthermore, it is only necessary to provide a layer with increased thermal conductivity where temperature peaks can occur in the insert element. Preferably, the layer with increased thermal conductivity can be provided in an area surrounding the area with high temperature peaks.This allows heat to be dissipated efficiently, preventing thermal failure. The remaining area of ​​the insert element can be coated with a layer with different properties. This ensures safe operation even under thermal stress, while also providing an insert element optimized for other properties.

[0016] The insert element preferably further comprises a core layer arranged on the second insert element side, wherein the core layer differs from the primary layer and / or the secondary layer with regard to at least one material property. The core layer or core ply can be a third layer that has different properties compared to the primary layer and / or the secondary layer. For example, the core layer can be in contact with a substrate and be optimized to fix the insert element to the substrate. In other words, the core layer can be designed to fasten the insert element to a substrate, for example a structure or a rim. For example, the core layer can be designed such that it can exert a clamping force on a rim and can thus hold the insert element securely to the rim.

[0017] Preferably, the secondary layer extends at least partially in the width direction in cross-section. In other words, the secondary layer can be provided exclusively in sections in the width direction. This allows a material property of the secondary layer to be provided specifically at designated locations in the cross-section of the insert element. For example, the secondary layer can have increased thermal conductivity. If the secondary layer is then only arranged adjacent to a central region of the insert element, the secondary layer can dissipate the heat from there to edge regions. Furthermore, it is conceivable for the secondary layer to have a greater hardness than the primary layer and thus be able to support certain regions in the cross-section of the insert element. This prevents the insert element from excessively deforming under the influence of an external force.

[0018] The insert element can preferably have a geometric shape for receiving and guiding the element, in particular the rope or cable. The geometric shape can correspond to the shape of the element to be guided. This can increase the contact area between the element to be guided and the insert element. Furthermore, it can be ensured that, in the case where the element is a rope or cable, it is securely guided in a specific area of ​​the insert element. The geometric shape can, for example, be an approximately semicircular cutout on the first side of the insert element. The rope can then be placed in this cutout.

[0019] Preferably, the secondary layer extends in cross-section in the width direction exclusively in the region of the geometric shape. Because the cable guided through the insert element is guided in a stationary manner (i.e. with a fixed position in the width direction) in the geometric shape, particularly high loads arise in the insert element in this region. This can be counteracted by providing the secondary layer in the width direction, in particular exclusively, in this region. For example, the secondary layer, which for example has optimized rigidity, can be arranged in the width direction exclusively in the region of the geometric shape. In this case, the secondary layer can be provided in the insert element at a distance from the first insert element side.For example, by increasing the hardness of the secondary layer compared to the primary layer, the flexing work introduced into the insert element can be reduced or avoided, thereby reducing heat input into the insert element. A primary layer with, for example, sound and / or vibration-damping properties can be provided around the secondary layer. This allows for a particularly durable insert element to be achieved with very good damping properties. Optimized stiffness can be understood as the maximum possible stiffness without losing vibration and / or damping properties.

[0020] Preferably, in cross-section, the secondary layer is arranged adjacent to the geometric shape. In other words, the geometric shape can be formed exclusively in the secondary layer. In this embodiment, the secondary layer can be provided on the first side of the insert element. In other words, the secondary layer can be provided on the surface of the insert element. This is advantageous if the secondary layer has a certain coefficient of friction and / or wear resistance, which provides advantages for the durability of the insert element in direct contact with the rope or cable to be guided.

[0021] Preferably, the secondary layer is provided at a low point of the geometric shape. In other words, the secondary layer can only be provided in sections of the geometric shape. Depending on the rope and lining geometry, the highest loads sometimes occur at the low point of the geometric shape. Therefore, it can be advantageous to reinforce this area, particularly with the secondary layer with appropriate properties. For example, the area around the low point can be covered with a particularly hard material. This can increase the overall longevity of the insert element.

[0022] Preferably, the secondary layer extends at least partially in the radial direction in cross-section. In other words, the secondary layer can be provided exclusively in sections in the radial direction in cross-section. Thus, the secondary layer can be surrounded by the primary layer in the radial direction. This makes it possible to provide properties inside the insert element without the secondary layer coming into contact with the environment on a surface of the insert element. This is advantageous, for example, when the secondary layer is particularly susceptible to weathering or the like. Preferably, the insert element further comprises a fiber-reinforced inner layer, which is arranged on the second insert element side. The inner layer can advantageously be used to secure the insert element to a rim. Furthermore, the fiber-reinforced inner layer can stabilize the insert element as a whole.

[0023] Preferably, the primary layer and / or the secondary layer comprise at least one elastomer based on SBR, BR, NR, IR, EPM / EPDM, HR / X-IIR, NBR, HNBR, CR, PE, PP, CPE, PVC, CSM, and / or a combination thereof. SBR (styrene-butadiene rubber) can be present, for example, as emulsion and solution SBR, and / or high-styrene SBR. SBR can exhibit good mechanical properties, extremely good abrasion, and good resistance to permanent deformation. Furthermore, SBR is advantageously resistant to Freon, glycols, and brake fluids. BR (butadiene rubber) has excellent elastic properties, exhibits good abrasion, and can be blended particularly easily with SBR, NR, IR, and NBR. Furthermore, BR has moderate resistance to seawater, acids, and bases. NR (natural rubber) has excellent mechanical properties, very good elastic properties and good abrasion.NR offers medium resistance to seawater, acids and bases, and other medium concentrations. IR (polyisoprene rubber) exhibits good mechanical resistance, good elastic properties, and is particularly advantageous for mixing with SBR and NR. IR also offers medium resistance to seawater, acids and bases, and medium concentrations.

[0024] EPDM (ethylene propylene diene rubber) exhibits very good resistance to heat, high temperatures, and ozone, as well as high resistance to permanent deformation. Furthermore, EPDM offers good resistance to water and glycols, as well as to aggressive chemical oxidation. NBR (nitrile rubber) exhibits good resistance to oils, good mechanical properties, and good to excellent gas and air permeability.

[0025] HNBR (hydrogenated nitrile rubber) exhibits very good mechanical properties, very good heat resistance up to 51°C, excellent abrasion resistance, and excellent resistance to permanent deformation. CR (chloroprene rubber) exhibits good resistance to ozone and seawater, good flame resistance, and good resistance to animal and vegetable fats. EE (polyethylene) exhibits high resistance to acids, alkalis, solvents, and other chemicals. PE also exhibits good electrical insulation and good sliding behavior. In contrast, its mechanical properties are only mediocre. PP (polypropylene) exhibits good electrical insulation. CPE (chlorinated polyethylene rubber) exhibits particularly good aging resistance and ozone resistance. PVC (polyvinyl chloride) is particularly easy to process.CSM (chlorosulfonated polyethylene) exhibits excellent mechanical properties, very good flame and heat resistance, resistance to ozone and weathering, and excellent gas and air permeability. CSM is very resistant to strong oxidizing agents and has very good resistance to salt water, saline solutions, alcohols, and hydrochloride. Due to the material options mentioned above, the primary layer and the secondary layer can be made of the corresponding materials or a combination of several materials, depending on their area of ​​application and the desired properties. The use of SBR, BR, and NR, or a combination thereof, is particularly preferred. The primary layer can comprise BR as the main material. BR offers very good dynamic properties and low abrasion. In addition, the primary layer can comprise NR. The secondary layer can comprise SBR and NR as the main material.In addition, the secondary layer may comprise BR and a filler.

[0026] The primary layer and / or the secondary layer preferably comprises TPA, TPC, TPO, TPS, TPU, TPV or cross-linked olefin-based thermoplastic elastomers, rubber-synthetic resin mixtures, PTFE and / or a combination thereof. TPA here describes thermoplastic polyamide elastomers, TPC (thermoplastic copolyester elastomers), TPO (olefin-based thermoplastic elastomers), predominantly PP / EPDM, TPS thermoplastic styrene block copolymers such as SBS, SEBS, SEPS, SEEPS and MBS, TPU (thermoplastic elastomers based on ethylene oxide) or TPV (thermoplastic vulcanizates). Preferably, a primary layer can be formed from an elastomer and the secondary layer from a thermoplastic, or the primary layer from a thermoplastic and the secondary layer from an elastomer. For additional layers, at least one polymeric and at least one elastomeric layer in the overall composite can be advantageous.These combinations also have effects that extend service life, reduce wear, reduce vibrations, and optimize conductivity.

[0027] The insert element preferably comprises reinforcement in the form of fibers, threads, cords, or fabrics made of glass, carbon, rock wool, metal wool, titanate, aluminum silicate and aluminum oxide, ceramic, silicon carbide, iron and copper and their alloys, polyamide, polyacrylonitrile, polyester, phenol, aramid, cotton, cellulose, and / or a combination thereof. The reinforcements can be added additionally to realize special properties of the primary layer and / or the secondary layer. Preferably, the reinforcement is provided adjacent to the first insert element side. The reinforcement can be provided exclusively on the first insert element side. This makes it possible to avoid or reduce local deformations of the insert element upon contact with a guided element (e.g., rope).

[0028] Preferably, the secondary layer has a round or oval cross-sectional shape. In other words, the geometric design of the secondary layer can further enhance and / or precisely implement the desired property that the secondary layer is intended to achieve. For example, the oval cross-section can offer greater resistance to deformation. Furthermore, it can be used to cover a specific area in the cross-section of the insert element where certain loads occur (e.g., flexion movements) with the secondary layer in a targeted manner in order to locally implement the desired properties.

[0029] The primary layer and / or the secondary layer preferably has a conductivity of <100 ohms x cm. This means that at least one of the layers can be implemented as a conductive layer. This enables potential equalization. Consequently, the copper brushes or the like used to date in the prior art, which are in contact with a cable to be guided, can be omitted and the corresponding property can be provided via the insert element. Furthermore, the primary layer and / or the secondary layer can also be designed to be insulating. This is particularly advantageous if a signal is to be transmitted via the cable (e.g. a cable car). Such a signal can then be received by signal receivers. An insulated insert element is advantageous for conducting the interference signal through the cable.

[0030] The insert element preferably comprises a tertiary layer which differs from the primary layer and / or the secondary layer with respect to at least one material property. A third layer can be used to implement further properties in the insert element. The same design options apply to the tertiary layer as to the primary layer and the secondary layer. Furthermore, a quaternary layer can also be provided. A fourth layer of this type, which can differ from the primary layer, the secondary layer, and / or the tertiary layer with respect to at least one material property, can be used to implement a further desired property in the insert element. Thus, a three-layer structure of the insert element can be provided. However, further layers can also be provided. For example, a quaternary layer can be provided, resulting in a four-layer structure of the insert element.Overall, a plurality of layers can be provided. Each of the layers can be individually configured to achieve the desired properties of the insert element. In other words, each of the layers can have the configurations of the primary layer and / or the secondary layer described herein.

[0031] The secondary layer preferably has sound-dampening properties. For cable cars in urban areas, it is particularly important to keep downtimes of the system as short as possible. In urban areas, 24 / 7 operation can be assumed, so the environmental conditions are different from those in alpine applications, for example. In other words, service lives achieved to date of, for example, 30,000 km of guided rope in urban applications can lead to multiple replacement of the insert elements per year, which would entail correspondingly higher expenditure for replacing the insert elements. Furthermore, much higher demands are placed on sound absorption. Therefore, the problem of sound immission can be addressed by providing a secondary layer that has particularly sound-dampening properties. The secondary layer can comprise a softer material than the primary layer.The primary layer can ensure the necessary service life through the appropriate use of harder or wear-resistant materials.

[0032] Preferably, the secondary layer can be designed as a weather-resistant cover layer. Weather-resistant layers of prior art insert elements usually resulted in the problem that other properties of the insert elements were negatively affected, resulting in problems with durability and / or noise emissions. Because in one embodiment of the present invention only the secondary layer can be weather-resistant, the primary layer can accordingly ensure that other properties of the insert element are provided. This allows the insert element to have a longer service life overall.

[0033] Preferably, the secondary layer and the primary layer are detachably connected to one another. In the case 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, since the inner layer is certainly capable of being reused. In other words, the use of an optimized core material can make it possible to use the core material for longer than is usually the case with a homogeneous insert lining. Thus, the overall service life can be advantageously increased by applying a new cover layer. Depending on the retreading process technology, different areas of the insert element can be reused. The separability between the primary layer and secondary layer can be provided, for example, by a separating layer.Furthermore, the secondary layer and the primary layer can also be bonded together, and in the event of a replacement, the layer to be removed can be milled or turned, for example. It is also conceivable for the secondary layer and the primary layer to be bonded together in a form-fitting and / or force-fitting manner. This allows for particularly simple replacement.

[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 an advantageous clamping force of the insert element on a rim.

[0035] Preferably, the primary layer has a greater extension in the radial direction than the secondary layer. In other words, the primary layer can be thicker in the radial direction or the vertical direction than the secondary layer. This allows a longer service life to be achieved in the case where the primary layer is provided on the first side of the ply element and therefore comes into contact with the rope or cable to be guided. In this case, the secondary layer can have sound- or emission-damping properties. It has been found that both goals, namely emission reduction and increased longevity, can be achieved.

[0036] The insert element is preferably designed as an annular insert element, and wherein a ratio of the inner diameter to an outer diameter is preferably in a range from 0.3 to 0.9, in particular from 0.7 to 0.85. The first range has proven particularly advantageous when the insert element is used in cable cars in alpine areas. The range from 0.7 to 0.85 has proven particularly advantageous with regard to reducing noise emissions, which is why such an insert element is particularly suitable for use in urban or noise-regulated areas. The primary layer preferably has an extension length in the radial direction in a range from 10% to 90%, preferably 20% to 80%, of the extension length of the secondary layer in the radial direction.In the first area, it was discovered that only a very small portion of the energy introduced into the insert element is converted into thermal energy, with the remainder being released again as kinetic energy. In this case, each secondary layer can be surrounded by a primary layer. The secondary layer can be arranged radially inside the insert element. This allows the dynamic property to be realized when the insert element is loaded in such a way that the energy introduced into the system is dissipated again, and advantageously, little thermal energy is generated. This avoids local temperature peaks inside the insert element, thus preventing thermal failure due to carbonization.Preferably, thermal energy input into the insert element can be reduced or minimized by applying the secondary layer across the entire width of the cross-section, especially in the dynamically loaded area below the contact point between the insert element and the element to be guided. In the second area, it has been shown that the insert element exhibits an increased service life even under dynamic loads.

[0037] Preferably, a ratio of the extension length of the primary layer in the width direction to an extension length in the secondary layer in the width direction is in a range between 1.1 and 2.5. In other words, the secondary layer can be provided only in sections in the width direction. This is particularly advantageous if the contact region between the insert element and an element to be guided is designed to be replaceable. In other words, the primary layer can remain, whereas the secondary layer, which is only provided in sections in the width direction, is replaced. This makes it possible to realize a particularly environmentally friendly insert element which is at least partially renewable. The above section primarily described the primary layer and the secondary layer. However, further layers can also be provided.For example, the tertiary layer can have properties and / or configurations like the primary layer or the secondary layer.

[0038] Given the increasing demand for sustainable products, a multi-layered structure of an insert element can contribute to the need to use fewer high-performance materials and the associated raw materials, thus enabling the use of more sustainable, but potentially less resilient materials. Furthermore, the separation into recyclable and non-recyclable materials can be carried out efficiently and effectively. Furthermore, the multi-layer insert element can use "green" raw materials, making recycling of the insert element easier.

[0039] In the above section, a two-layer insert element was mainly described, but several layers (for example, 3 or more) can also be provided.

[0040] According to a further aspect of the present invention, a roller system is provided, in particular for guiding a rope or cable, in particular for a cable car system, comprising a rim, and an insert element according to one of the preceding embodiments, wherein the insert element is mounted on the rim such that it is rotatable together with the rim.

[0041] According to a further aspect of the present invention, a method for producing an insert element, in particular for guiding a rope or cable, in particular for a cable car system, is provided, comprising the following steps: providing a primary layer and a secondary layer that differ with respect to at least one material property, and bonding the primary layer to a secondary layer by compression molding, injection molding, extrusion molding, extrusion, casting, winding, printing, and / or vulcanization. Preferably, the above method produces an insert element according to one of the above embodiments. Preferably, the method further comprises mechanical post-processing of the insert element by turning or milling.

[0042] Individual features of the embodiments can be combined with other features or other embodiments to form new embodiments. Embodiments and advantages mentioned in connection with the embodiments or features then also apply analogously to the new embodiments. Embodiments and advantages mentioned in connection with the device also apply analogously to the method, and vice versa.

[0043] In the following, preferred embodiments are described in detail with reference to the attached figures.

[0044] It shows:

[0045] Fig. 1 is a perspective schematic view of an insert element according to an embodiment of the present invention.

[0046] Fig. 2 is a schematic cross-section through a part of an insert element according to an embodiment of the present invention,

[0047] Fig. 3a and Fig. 3b show a schematic cross section of an insert element according to an embodiment of the present invention.

[0048] Fig. 4a to Fig. 4c each show a schematic cross section through an insert element according to an embodiment of the present invention,

[0049] Fig. 5a and Fig. 5b show a schematic cross section through an insert element according to an embodiment of the present invention, and

[0050] Fig. 6 is a flow chart of a method for producing a

[0051] Insert element according to an embodiment of the present invention.

[0052] Inlay elements are generally considered safety components and are subject to strict approval criteria. The typical maximum permissible surface pressure in the profile is 6 N / mm 2 For highly stressed insert elements, surface pressures of up to 9 N / mm 2permissible. For values ​​above this, up to 20 N / mm 2 influences that reduce service life can be expected. These operating conditions are tested using finite element simulations, dynamic testing on test benches, or on the system itself. The service life of insert elements is usually specified in kilometers of guided rope. However, there are also figures that state operating hours. Occurring loads include rope forces, normal forces, surface pressures, rope and insert element geometry, system operating speeds, ambient conditions, clamping / installation forces, and dimensions of the insert element, as well as material data / properties of the insert element, as well as service and inspection regulations. Despite all this, an insert element is a wearing part in the rope or rail guide, and a wide variety of wear and failure causes are known.

[0053] Typically, the insert elements are replaced due to wear or cracks on the surface. The standards specified by the system manufacturer or the applicable standards apply. Abrasion occurs when the material of the insert element is worn away at the base of the profile or on the side flank due to relative movement between the insert element and the rope / rail, also in combination with misalignment or tracking of the rope on the insert element. Wear is therefore measurable. Vibrations or impacts, or an inappropriate rope diameter can also lead to excessive abrasion. Cracks occur, for example, due to material aging or mechanical overload. Furthermore, there are various types of breakouts: material destruction caused by oils and greases, slipping of the rings, cracks (including due to an overly tight press fit on the pulley body), breakouts caused by off-centered rope guidance, and the like.

[0054] The current state of the art uses materials that represent a compromise of target parameters such as dynamic properties (heat built-up), mechanical properties (wear), electrical conductivity, noise emission, friction and braking properties, and weather resistance. The composition of the compounds, as well as the current structure and geometry of the insert elements, are sufficient for most current applications.

[0055] Fig. 1 is a schematic and perspective illustration of an insert element 1 according to an embodiment of the present invention. The insert element 1 has a first insert element side 4 and an opposite insert element side 6. Furthermore, an element of the present embodiment is designed as a ring-like insert element and configured to rotate about a rotation axis D. Furthermore, the insert element 1 has a geometric formation 7 on the first insert element side 4. The geometric formation corresponds in cross-section to the shape of an element to be guided. In the present embodiment, a cable (not shown in Fig. 1) is guided through the insert element 1. The geometric formation 7 is designed depending on the cable to be guided.

[0056] Fig. 2 is a cross-section through the insert element 1 from Fig. 1. More precisely, the insert element 1 from Fig. 1 together with a rim 10 forms a roller system 100 according to an embodiment of the present invention. Furthermore, the element 8 to be guided, in this case a cable, is shown in section. The cable 8 comes to lie in the geometric shape 7 of the insert element 1. In the embodiment shown in Fig. 2, the guide direction extends into the plane of the page. Fig. 3a is a cross-section through the insert element 1 according to an embodiment of the present invention. The insert element 1 has a primary layer 2 and a secondary layer 3. The primary layer 2 and the secondary layer 3 differ from one another with regard to at least one material property.Furthermore, the geometric formation 7 can be seen on the first insert element side 4, which is designed to come into contact with a rope and guide it. The radial direction or vertical direction R and the width direction B are also shown. The secondary layer is only provided in the area of ​​the geometric formation 7 in the width direction B. In the present embodiment, the secondary layer has a dynamically optimized material which introduces only very little thermal energy into the insert element when loaded. More precisely, the secondary layer 3 is designed such that little flexion takes place, whereby the thermal energy introduced into the insert element 1 can be significantly reduced. The design of the material ensures that the dynamically introduced energy is released again.Thus, thermal failure due to carbonization can be avoided in the radial direction below the geometric shape 7, since little or no thermal energy is introduced into the insert element by the pressure of the cable. Furthermore, the insert element of the present embodiment has a reinforced inner layer 9, which is designed to come into contact with a rim. This allows the insert element 1 to be secured to the rim particularly reliably.

[0057] Fig. 3b is a schematic cross-section through an insert element 1 according to a further embodiment of the present invention. The difference from the embodiment of Fig. 3a is that the secondary layer 3 extends in the width direction across the entire width of the insert element 1. As a result, the effect of the previously described embodiment can be achieved across the entire width in the width direction B of the insert element 1. This is particularly advantageous when the exact contact point between the insert element 1 and an element to be guided is not predetermined. A further advantage of this structure can be the easier introduction of the secondary layer during the lining production process.

[0058] Fig. 4a is a schematic cross-section through an insert element 1 according to an embodiment of the present invention. In the embodiment shown in Fig. 4a, the mechanical optimization of the insert element 1 is realized at the interface to the rope. This allows for significantly lower abrasion and less breakout behavior of the cover layer. Depending on the manufacturing process, there are various options for positioning the mechanically optimized cover layer. In Fig. 4a, the secondary layer 3 is located at the rope base of the geometric formation 7. Depending on the rope and lining geometry, the highest loads sometimes occur in the rope base, whereby the greatest extension of the service life can be achieved here by providing a particularly resistant material.

[0059] Fig. 4b shows a further embodiment of the present invention, in which the wear-resistant secondary layer 3 is provided over the entire outer region of the insert element. This is particularly advantageous when other contact surfaces outside the geometric shape 7 may temporarily occur. Furthermore, the secondary layer 3 can have a weather-resistant property, whereby the insert element can have an increased service life even under adverse weather conditions.

[0060] In Fig. 4c, the secondary layer 3 is provided as a mechanically reinforced or wear-resistant layer as a lining of the geometric formation 7.

[0061] Overall, in all embodiments shown in Figures 4a to 4c, the contact surface between the rope and the insert element is lined with a wear-resistant secondary layer 3.

[0062] Fig. 5a shows another insert element 1 according to another embodiment of the present invention. In the present embodiment, the insert element 1 comprises a secondary layer 3 that has optimized conductivity throughout the entire outer region (i.e., on the first insert element side 4). This enables advantageous signal transmission behavior of the insert element 1. Furthermore, the primary layer 2 of the present embodiment has improved dynamic strength.

[0063] Likewise, the secondary layer 3 can also provide desired insulation.

[0064] Fig. 5b shows a further embodiment of the present invention in which the secondary layer 3 can be renewed in a simple manner. For example, it is sufficient for the secondary layer to be renewed only in the area around or adjacent to the geometric formation 7. Furthermore, it is conceivable that the entire section of the insert element facing the first insert element side is also renewed.

[0065] Fig. 6 is a flowchart schematically showing the sequence of a method for producing 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 with respect to 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 molding, casting, winding, printing, and / or vulcanization.

[0066] Step S3 is an optional step and includes mechanical finishing of the insert element by turning or milling.

[0067] List of reference symbols

[0068] 1 insert element

[0069] 2 Primary layer

[0070] 3 Secondary layer

[0071] 4 first insert element side

[0072] 6 second insert element side 7 geometric shape

[0073] 8 element to be led

[0074] 9 reinforced inner layer

[0075] 10 rim 100 roller system

[0076] D axis of rotation

[0077] R Radial direction

[0078] B Width direction

Claims

Claims 1. An insert element (1), in particular for guiding a rope or cable, in particular for a cable car system, comprising: a primary layer (2), and a secondary layer (3) provided in and / or on the primary layer (2), wherein the insert element (1) has a first insert element side (4) designed to come into contact with an element (8), in particular a rope or cable, to be guided in a guide direction, in particular in a circumferential direction, and a second insert element side (6) opposite the first insert element side (4), wherein the primary layer (2) and the secondary layer (3) differ with respect to at least one material property, wherein the insert element (1) has a substantially constant cross-section along the guide direction, and wherein the insert element (1) extends in the cross-section in a radial direction (R) and a width direction (B),which are orthogonal to the guide direction and to each other.

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

3. Insert element (1) according to claim 1 or 2, wherein the secondary layer (3) is arranged at least in sections on the first insert element side (4).

4. Insert element (1) according to one of the preceding claims, wherein the at least one material property comprises wear resistance, heat build-up, conductivity, sound damping, vibration damping, friction coefficient, weather resistance and / or thermal conductivity.

5. Insert element (1) according to one of the preceding claims, wherein the insert element (1) further comprises a core layer arranged on the second insert element side (6), wherein the core layer differs from the primary layer (2) and / or the secondary layer (3) with regard to at least one material property.

6. Insert element (1) according to one of the preceding claims, wherein in cross-section the secondary layer (3) extends at least partially in the width direction (B).

7. Insert element (1) according to one of the preceding claims, wherein the insert element (1) has a geometric shape (7) for receiving and guiding the element (8), in particular the rope or cable.

8. Insert element (1) according to claim 7, wherein the secondary layer (3) extends in cross-section in the width direction (B) exclusively in the region of the geometric shape (7).

9. Insert element (1) according to claim 7 or 8, wherein in cross section the secondary layer (3) is arranged adjacent to the geometric formation (7).

10. Insert element (1) according to one of claims 7 to 9, wherein the secondary layer (3) is provided at a low point of the geometric formation (7).

11. Insert element (1) according to one of the preceding claims, wherein the secondary layer (3) extends in cross-section in the radial direction (R) at least in sections.

12. Insert element (1) according to one of the preceding claims, wherein the insert element (1) further comprises a fiber-reinforced inner layer (9) which is arranged on the second insert element side (6).

13. Insert element (1) according to one of the preceding claims, wherein the primary layer (2) and / or the secondary layer (3) comprise 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 a combination thereof.

14. Insert element (1) according to one of the preceding claims, wherein the primary layer (2) and / or the secondary layer (3) comprises TPA, TPC, TPO, TPS, TPU, TPV or crosslinked olefin-based thermoplastic elastomers, rubber-synthetic resin mixtures, PTFE and / or a combination thereof.

15. Insert element (1) according to one of the preceding claims, wherein the primary layer (2) is formed from an elastomer and the secondary layer (3) is formed from a thermoplastic or wherein the primary layer (2) is formed from a thermoplastic and the secondary layer (2) is formed from an elastomer.

16. Insert element (1) according to one of the preceding claims, wherein in cross section the secondary layer (3) has a round or oval cross-sectional shape.

17. Insert element (1) according to one of the preceding claims, wherein the insert element (1) comprises a reinforcement in the form of fibers, threads, cords or fabrics made of glass, carbon, rock wool, metal wool, titanate, aluminum silicate and aluminum oxide, ceramic, silicon carbide, iron and copper and their alloys, polyamide, polyacrylonitrile, polyester, phenol, aramid, cotton, cellulose and / or a combination thereof.

18. Insert element (1) according to one of the preceding claims, wherein the secondary layer (3) has a round or oval cross-sectional shape in cross section.

19. Insert element (1) according to one of the preceding claims, wherein the primary layer (2) and / or the secondary layer (3) has a conductivity of <100 Ohm x cm.

20. Insert element (1) according to one of the preceding claims, further comprising a tertiary layer which differs from the primary layer (2) and / or the secondary layer (3) with respect to at least one material property.

21. Insert element (1) according to one of the preceding claims, wherein the secondary layer (3) has sound-damping properties.

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

23. Insert element (1) according to one of the preceding claims, wherein the secondary layer (3) and the primary layer (2) are detachably connected to one another.

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

25. Insert element (1) according to one of the preceding claims, wherein the primary layer (2) has a greater extension in the radial direction (R) than the secondary layer (3).

26. Insert element (1) according to one of the preceding claims, wherein the insert element (1) is designed as an annular insert element (1), and wherein preferably a ratio of the inner diameter to an outer diameter is in a range from 0.3 to 0.9, in particular from 0.7 to 0.

85.

27. Insert element (1) according to one of the preceding claims, wherein the primary layer (2) has an extension length in the radial direction (R) in a range of 10% to 90%, preferably 20% to 80%, of the extension length of the secondary layer (3) in the radial direction (R).

28. Insert element (1) according to one of the preceding claims, wherein a ratio of the extension length of the primary layer (2) in the width direction (B) to an extension length in the secondary layer (3) in the width direction (B) is in a range between 1.1 and 2.

5.

29. Roller system (100), in particular for guiding a rope or cable, in particular for a cable car system, comprising a rim (10), an insert element (1) according to one of the preceding claims, wherein the insert element (1) is mounted on the rim (10) in such a way that it is rotatable together with the rim (10).

30. Method for producing an insert element (1), in particular for guiding a rope or cable, in particular for a cable car system, comprising the steps: Providing a primary layer (2) and a secondary layer (3) which differ with respect to at least one material property, and bonding the primary layer (2) to the secondary layer (3) by compression molding, injection molding, extrusion, casting, winding, printing and / or vulcanization.

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