Insert member, roller system, and method for manufacturing insert member

Abstract

An insert member (1) is provided, particularly for cableway facilities, and especially for guiding ropes or cables. The insert member (1) includes a primary layer (2) and a secondary layer (3) provided in and / or above the primary layer (2). The insert member (1) has a first insert member side (4) designed to contact a member (8), particularly a rope or cable, that is guided in the guiding direction, particularly in the circumferential direction, and a second insert member side (4) opposite to the first insert member side (4). The primary layer (2) and the secondary layer (3) differ with respect to at least one material property. The insert member (1) has an essentially constant cross-section along the guiding direction. In cross-section, the insert member (1) extends in the guiding direction and in the radial direction (R) and width direction (B), which are perpendicular to each other, respectively. Furthermore, a roller system (100) and a method for manufacturing the insert member are also provided.

Description

[Technical Field]

[0001] The present invention relates particularly to a cableway facility and particularly to an insert member for guiding ropes or cables, particularly to a cableway facility and particularly to a roller system for guiding ropes or cables, and to a method for manufacturing an insert member particularly to a cableway facility and particularly to guiding ropes or cables.

[0002] Insert members or insert linings are used to guide, deflect, and drive circulating ropes, or when a load is guided along a cableway or rail. Such insert members can take the form of closed or open rings, segments, or cords (longitudinal profiles). As a rule, one or more profiles (i.e., geometric shapes) with shapes and dimensions corresponding to the rope, web, or rail are incorporated on the side facing the rope or web / rail guide.

[0003] Known insert members typically include an outer layer that contacts the guided rope and a reinforced inner layer that ensures the insert member sits securely on a rim or the like. Furthermore, insert members are also known that can be fixed to rollers or the like on their sides using a clamping mechanism. In particular, this type of insert member does not require a reinforced inner insert, and the insert member consists of only one outer layer.

[0004] The outer and inner layers of known insert components are typically designed for a long service life. This ensures a sufficient service life for the insert component.

[0005] However, these designs, namely designs for long service life, present the problem of making it difficult or impossible to achieve other desired properties of the insert members. In particular, the increasing number of application fields for such insert members, such as applications in urban cable car systems, imposes more requirements on the insert members, such as vibration damping, noise damping, high conductivity, vibration damping characteristics and / or braking properties. [Overview of the project] [Problems that the invention aims to solve]

[0006] Therefore, the object of the present invention is to provide an insert member that can ensure a wider range of applications for the insert member. [Means for solving the problem]

[0007] The above objectives are achieved by an insert member having the features of claim 1, a wheel system having the features of claim 29, and a method for manufacturing an insert member having the features of claim 30.

[0008] According to one aspect of the present invention, an insert member is provided, particularly for cableway systems and especially for guiding ropes or cables. The insert member may include a primary layer and a secondary layer provided in and / or above the primary layer. The insert member may have a first insert member side designed to contact a member guided in the guiding direction, particularly in the circumferential direction, particularly a rope or cable, and a second insert member side opposite to the first insert member side. The primary and secondary layers may differ with respect to at least one material property. The insert member may have an essentially constant cross-section along the guiding direction. The insert member may extend radially and laterally in cross-section, with the radial and lateral directions being perpendicular to the guiding direction, respectively.

[0009] In conventionally known cableway rings (e.g., insert members), a compromise is made between the dynamic and mechanical behavior of the material. In contrast, according to one aspect of the present invention, the insert member has different layers (e.g., material layers) to improve both wear resistance and dynamic behavior. On the one hand, this results in a longer service life for the insert member, and on the other hand, it opens up new areas of application for high-stress applications. In other words, a multilayer composite system can be provided as an insert lining (i.e., insert member) for guiding, deflecting, and driving a circulating rope. The insert member can be a closed or open ring. Furthermore, the insert member can also be designed as an insert cord. The insert member can be fixed on a wheel or rim in an insert. Furthermore, the insert member can be provided, specifically clamped between two flange wheels. The insert member can be a separate part and can be designed to be fixed to a roller. The roller can be rotatably held sequentially on a structure, for example, a base material. For example, a roller can be rotatably mounted on a structure by a sliding bearing or a roller bearing. A rope or cable can be placed on an insert member and thereby supported and / or guided. The guiding direction (e.g., rope guiding direction) can specify the direction in which the guided rope extends. The insert member may also be designed to support the rope against lateral displacement perpendicular to the guiding direction. The insert member may have lower strength than the roller to which the insert member is fixed. In other words, the insert member may be formed from an elastic material that at least partially surrounds the guided rope. To improve the guiding properties, the insert member may be at least partially conformed to the shape of the guided rope. Furthermore, the insert member may be designed as a strand-shaped member that can be attached to a component to prevent direct contact between the rope or cable and the component.Furthermore, the insert member may be designed as an insert cord, positioned around or wrapped around a guide component. These guide components may be, for example, wheels or discs used to drive or deflect a rope. In such cases, the lining is generally connected to the wheel or disc by fastening or screw connections. In addition, the insert member may be designed to contact a rail or similar so that the rope or cable is not only guided but also guided on the rail. For example, the insert member may be provided as a wheel tire that can be attached to a wheel body. The primary and secondary layers may each be layers of volume extending in all three spatial directions. The secondary layer may be disposed entirely or partially within the primary layer. Furthermore, the secondary layer may be disposed on the surface of the primary layer. The insert member formed from the primary and secondary layers may have a first insert member side and a second insert member side. A layer within the scope of the present invention may be a planar layer having a predetermined and identifiable extent. In particular, particles, composite materials, etc., added to the casting compound, for example, during the casting of the insert member, cannot be considered layers. Such additives, in particular, form random, unspecified arrangements and are not intended to be layers in the sense of the present invention. The first insert member side can be oriented substantially parallel to the second insert member side. The first insert member side can be the side that contacts the rope or rail when the insert member is in use. The second insert member side can contact the rim, tire or other object to which the insert member is provided. The first and second insert member sides can be the largest sides of the insert member in terms of surface area. The sides of the insert member can be defined by the edges of the insert member. The guide direction can be the direction in which the rope, cable or rail passes through the insert member when the insert member is in use. The primary and secondary layers can be layers of different materials.This can be characterized, for example, by the fact that both layers have at least one different material property. As a result, the insert member can be provided with at least two layers that are different. As a result, a combination of properties of the insert member can be achieved to obtain an insert member that can be used more broadly as a whole. Thus, the insert member can be provided as a multilayer insert member having a hybrid structure in which the primary and secondary layers can be arranged in different positions and different combinations within the cross-section of the insert member. The cross-section of the insert member can be the cross-section in the main extending direction of the insert member. Furthermore, the cross-section can extend along the guiding direction of the insert member. If the insert member is designed as an annular member, the guiding direction can extend in the circumferential direction. In other words, a rope guided through the insert member can be guided tangentially along or through the insert member. A constant cross-section can mean that the spatial extent of the cross-section changes by 10% or less along the guiding direction or the direction in which the insert member extends. In other words, the distribution or arrangement of the primary and secondary layers in the cross-section of the insert member can also remain constant. Even if the insert member is cut at different positions along the guide direction, the layers can always be arranged in essentially the same way. In other words, this does not mean a random distribution of layers in the cross-section. Looking at the cross-section of the insert member (i.e., in a two-dimensional view of the cross-section), one extending direction can be defined as the width direction, and another extending direction at a 90° angle to the width direction can be defined as the radial direction. In other words, the width direction can extend along the side surface of the first insert member and / or along the side surface of the second insert member. The radial or perpendicular direction can also be a direction away from the side surface of the first insert member.By using different layers in the composite material of the insert member, undesirable intermediates in material development can be avoided, and by optimizing the arrangement and dimensionality of each layer, insert members with diverse properties can be provided. For example, it is possible to create an insert member having a dynamically optimized inner layer and a mechanically and / or wear-optimized outer layer. Furthermore, it is possible to adjust the conductivity of the outer and / or inner layers (e.g., signal transmission or equipotentialization). It is possible to achieve outer and / or inner layers that dampen noise or vibration. Additionally or alternatively, the friction and damping properties of the insert member can also be optimized. Furthermore, the weather resistance of the outer layer can also be optimized. In addition, the insert member can offer options for recycling the insert member and / or using recycled materials, and for improving the recyclability of the insert member.

[0010] Preferably, the primary and secondary layers are designed as elastomer layers or polymer layers, respectively. Using elastomers allows for optimal adjustment of the dynamic and wear-resistant properties of the insert member. For example, mixtures of different polymers can be provided for adjustment. Furthermore, at least one filler can be added to the polymer to adjust its specific properties. For example, carbon black and / or silica can be used as fillers. In addition to the internationally valid ASTM classification for carbon black, carbon black can also be classified into highly active, active, semi-active, and low-active carbon blacks. Highly active carbon black can have a large surface area, while low-active carbon black can have a small surface area. Using carbon black as a filler allows for adjustment of the conductivity of the layers. Furthermore, the use of highly active carbon black can enhance wear resistance. In contrast, the use of low-active carbon black can improve dynamic behavior (heat generation) compared to highly active carbon black. The heat generation can be measured according to the Goorich test (DIN 3533, ASTM D 623, ISO 4666 / 3, 4666 / 4, BS 903 part A50, or JIS K6265). Heat generation can be understood in a broad sense as how much heat is generated in the material under dynamic load, such as bending. Excessive heat generation in the material can be avoided by favorable dynamic behavior. This can counteract thermal failure of the material. Furthermore, the polymer or elastomer has improved vibration and noise damping compared to, for example, Becorit. In addition, the polymer or elastomer has a low coefficient of friction. Preferably, the secondary layer is a wear-resistant layer. The wear-resistant layer may have special mechanical properties to minimize wear. For example, the secondary layer can be provided on the side surface of the first insert member and thus come into direct contact with a rope, cable, or rail, and can be designed to reduce wear of the secondary layer due to its abrasion resistance when such contact occurs.In contrast, the primary layer can be designed with other properties to provide an overall advantageous insert member. Preferably, the secondary layer is disposed at least partially on the side surface of the first insert member. For example, the secondary layer can be provided only partially (i.e., partially exclusively) in the cross-section of the insert member. This can result in an insert member having both the primary and secondary layers on the surface of the insert member and on the side surface of the first insert member. The secondary layer can be designed to exhibit particularly low wear when in contact with a guided rope, cable, or rail. The primary layer can have material properties such as vibration damping, conductivity, and noise absorption to ensure properties other than wear resistance of the insert member. In this way, an insert member can be provided that can be used in a number of application fields.

[0011] Preferably, at least one material property includes abrasion resistance, heat generation, conductivity, noise damping properties, vibration damping properties, friction coefficient, weather resistance, and / or thermal conductivity. Abrasion resistance can be characterized by low wear during the operation of the insert member. Furthermore, abrasion resistance can also be achieved by high strength and / or high tear propagation resistance. As a result, the insert member is particularly durable and can be used for a long period of time. Heat generation or heat generation test can be measured according to the Goorich test (DIN 3533, ASTM D 623, ISO 4666 / 3, 4666 / 4, BS 903 part A50 or JIS K6265). Heat generation can be understood in a broad sense as how much heat is generated in the material under dynamic load, for example by bending. The insert member has an intrinsic electrical resistivity of ≤ 10 4 If the coefficient is Ω × cm, then it can be described as conductive. > 10 4 Ω × cm ~ ≤ 10 6 An insert member having an intrinsic electrical resistivity of Ω × cm can be described as an antistatic insert member. > 10 6 Ω × cm and ≤ 108 An insert member having an intrinsic electrical resistivity of Ω × cm can be said to be an electrically neutral insert member. > 10 8 An insert member having an intrinsic electrical resistivity of Ω × cm can be called an insulating insert member. This means that the insert member can be applied to areas of special applications (e.g., signal transmission, equipotentialization, etc.). For example, it is possible to use an insert member having at least two different layers, with the outer layer (e.g., primary layer) being conductive or insulating. In this case, the inner layer (e.g., secondary layer) can determine the dynamic behavior of the insert member. For example, current can be transmitted from the insert member through a flanged disk in contact with the insert member, via a rope. Furthermore, by providing only a conductive layer (e.g., primary or secondary layer), the insert member can be provided as a multi-component system that provides a mechanically optimized conductive material without obtaining an overall conductive system. Conductivity can be achieved, for example, by adding carbon black to one of the layers.

[0012] Soundproofing and / or vibration damping may be necessary, particularly in the case of cableway facilities in urban applications. Reduction of noise emissions can be achieved here. In the prior art, this problem is now solved by using materials optimized with respect to noise emission properties in the insert member, but this negatively impacts the expected service life of the insert member. The insert member of this embodiment provides a multilayer composite system that reduces the expected drawbacks of the noise emission reduction layer on the entire system (i.e., the entire insert member), because the noise emission reduction layer is used only partially or partially within the insert member, and layers with other properties can be provided, for example, dynamically optimized and / or providing increased wear resistance. The noise reduction properties can be optimized and modified by changing the radial thickness of the layers. This allows the insert member to be adapted to each location and application. Dynamically optimized can mean providing the lowest possible heat generation while simultaneously ensuring wear resistance.

[0013] According to O-Norm 12385-8 Section A.2.1 "Coefficient of friction," the coefficient of friction can be satisfied for an insert member under given operating conditions (e.g., dry or grease-added conditions). Since only one outer layer affects the coefficient of friction of the insert member, the entire system can be optimized by adding another layer not provided on the surface of the insert member. For example, a primary layer having the required coefficient of friction can be disposed on the side surface of the first insert member, while a secondary layer can ensure the required dynamic resistance of the insert member. In this way, the entire system can be optimized not only in terms of the coefficient of friction, but also in terms of other properties (e.g., dynamic properties or vibration damping properties). Dynamic resistance can indicate durability under dynamic load.

[0014] Furthermore, the layer provided on the side surface of the first insert member (either a primary or secondary layer) may include at least one material property, such as weather resistance. Weather resistance also focuses on the layer of the insert member that faces the environment (i.e., the outside world). Thus, for example, the primary layer, when disposed on the side surface of the first insert member, can be designed to be particularly weather-resistant. On the other hand, the secondary layer, disposed further inward in the radius or vertical direction, can ensure other properties of the insert member, such as dynamic resistance. Thus, with respect to climate change and the expansion of application fields, the insert member can be directly exposed to wind and rain, while at the same time optimizing its lifespan.

[0015] Thermal conductivity can represent how quickly heat can be dissipated from the inside of an insert member. For example, deformation of an insert member and the resulting bending action can generate heat inside the insert member. If this heat is not dissipated, it may lead to thermal damage due to carbonization. If layers (e.g., secondary and / or primary layers) are designed to have increased thermal conductivity, the generated heat can be easily dissipated from the inside of the insert member. As a result, thermal damage to the insert member can be avoided. Furthermore, providing layers with increased thermal conductivity is only necessary where temperature peaks can occur in the insert member. Preferably, layers with increased thermal conductivity can be provided in an environment with high temperature peaks. In this way, heat can be efficiently dissipated and thermal damage can be avoided. The remaining areas of the insert member can be provided with layers having other properties. This can ensure safe operation even under thermal stress and provide an insert member optimized for other properties.

[0016] Preferably, the insert member further includes a core layer disposed on the side surface of the second insert member, the core layer differing from the primary and / or secondary layers in at least one material property. The core layer may be a third layer having different properties compared to the primary and / or secondary layers. For example, the core layer may be in contact with a substrate and may be optimized for fixing the insert member to the substrate. In other words, the core layer may be designed to fix the insert member to a substrate such as a structural member or rim. For example, the core layer may be designed in such a way that it can apply a clamping force to the rim, thereby securely holding the insert member on the rim.

[0017] Preferably, the secondary layer extends at least partially in the width direction in the cross-section. In other words, the secondary layer can be provided only partially in the width direction. This means that the material properties of the secondary layer can be provided in particular at specified points in the cross-section of the insert member. For example, the secondary layer can have increased thermal conductivity. In that case, the secondary layer can be positioned adjacent to the central region of the insert member, allowing heat from there to be dissipated to the surrounding region. Also, the secondary layer has higher hardness than the primary layer, thereby supporting a predetermined region in the cross-section of the insert member. This can prevent the insert member from deforming excessively under the influence of external forces.

[0018] Preferably, the insert member may have a geometrically shaped portion for holding and guiding a member, particularly a rope or cable. The geometrically shaped portion may correspond to the shape of the member being guided. This can increase the contact surface between the member being guided and the insert member. Furthermore, if the member is a rope or cable, it can be ensured that it is safely guided within a predetermined area of ​​the insert member. The geometrically shaped portion may be, for example, a substantially semicircular notch on the side of the first insert member, and the rope can be placed in this notch.

[0019] Preferably, the secondary layer extends in the width direction only in the region of the geometric shape in the cross-section. The fact that the loop guided through the insert member does not move in the geometric shape (i.e., is in a fixed position in the width direction) results in a particularly high load on the insert member in this region. This can be counteracted by providing the secondary layer in the width direction, specifically in this region only. For example, a secondary layer with optimized rigidity can be arranged in the width direction only in the region of the geometric shape. In this case, the secondary layer can be provided at a distance from the side surface of the primary insert member. For example, the higher stiffness of the secondary layer compared to the primary layer can reduce or avoid the bending action introduced into the insert member, thereby reducing the heat introduced into the insert member. For example, a primary layer having noise and / or vibration damping properties can be provided around the secondary layer. This can result in a particularly robust insert member with very good damping properties. Optimized stiffness can be understood as the maximum possible stiffness when there is no vibration and / or when damping characteristics are no longer perceived.

[0020] Preferably, the secondary layer is disposed adjacent to the geometric shape portion in cross-section. In other words, the geometric shape portion can be formed only in the secondary layer. In this embodiment, the secondary layer can be provided on the side surface of the first insert member. In other words, the secondary layer can be provided on the surface of the insert member. This is advantageous if the secondary layer has a predetermined coefficient of friction and / or wear resistance, which is advantageous with respect to the durability of the insert member that is in direct contact with the guided rope or cable.

[0021] Preferably, the secondary layer is provided at the lower points of the geometric shape. In other words, the secondary layer can be provided only partially to the geometric shape. Depending on the dimensions and shape of the rope and lining, the maximum load may occur at the lower points of the geometric shape. Therefore, it may be advantageous to reinforce this area in particular with a secondary layer having corresponding properties. For example, a particularly hard material can be provided in the area surrounding the lower points. This can increase the overall durability of the insert member.

[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 only partially in the radial direction in cross-section. Thus, the secondary layer can be radially surrounded by the primary layer. This allows properties to be provided within the insert member without the secondary layer coming into contact with the environment on the surface of the insert member. This is advantageous, for example, when the secondary layer is particularly susceptible to the effects of wind and rain.

[0023] Preferably, the insert member also includes a fiber-reinforced inner layer disposed on the side surface of the second insert member. The inner layer can be advantageously used to secure the insert member to the rim. Furthermore, the fiber-reinforced inner layer can stabilize the insert member as a whole.

[0024] Preferably, the primary and / or secondary layers include at least one elastomer based on SBR, BR, NR, IR, EPM / EPDM, IIR / XX-IIR, NBR, HNBR, CR, PE, PP, CPE, PVC, CSM, and / or combinations thereof. SBR (styrene-butadiene rubber) can exist, for example, as emulsion and solution SBR and / or high-styrene SBR. SBR can have good mechanical properties, very good abrasion resistance and good permanent deformation resistance. SBR is also advantageously resistant to Freon, glycols and brake fluids. BR (butadiene rubber) has excellent elasticity and good abrasion resistance and is particularly miscible with SBR, NR, IR, and NBR. BR also has moderate resistance to seawater, acids and bases. NR (natural rubber) has excellent mechanical properties, very good elasticity and good abrasion resistance. NR has moderate resistance to seawater, acids and bases, and other media concentrates. IR (polyisoprene rubber) has good mechanical resistance and good elasticity, and is particularly suitable for mixing with SBR and NR. IR also has moderate resistance to seawater, acids and bases, and media concentrates. EPDM (ethylene propylene diene rubber) has very good resistance to heat, high temperatures, and ozone, and has high permanent deformation resistance. EPDM also has good resistance to water, glycols, and aggressive chemical oxides. NBR (nitrile rubber) has good oil resistance, good mechanical properties, and good to excellent gas permeability and breathability. HNBR (hydrogenated nitrile rubber) has good mechanical properties, very good heat resistance up to 51°C, excellent abrasion resistance, and excellent permanent deformation resistance. CR (chloroprene rubber) has good ozone resistance, seawater resistance, good flame resistance, and good resistance to animal and vegetable fats. EE (polyethylene) has high resistance to acids, alkalis, solvents, and other chemicals. PE also has good electrical insulation properties and good sliding properties. In contrast, its mechanical properties are only average. PP (polypropylene) has good electrical insulation properties.CPE (chlorinated polyethylene rubber) has particularly good aging resistance and ozone resistance. PVC (polyvinyl chloride) is particularly easy to process. CSM (chlorosulfonated polyethylene) has excellent mechanical properties, very good flame resistance and heat resistance, ozone resistance, weather resistance, and excellent gas permeability and breathability. CSM has high resistance to strong oxidants and very good resistance to salt water, salt solutions, alcohols, and hydrochlorides. With the above material options, the primary layer and the secondary layer can be produced from the corresponding materials or combinations of several materials, depending on their application fields and desired properties. It is particularly preferred to use SBR, BR, and NR, or combinations thereof. The primary layer can contain BR as the main material. BR provides very good dynamic properties and low wear. The primary layer can also contain NR. The secondary layer can contain SBR and NR as the main materials. In addition, the secondary layer may contain BR and fillers.

[0025] Preferably, the primary layer and / or the secondary layer contain TPA, TPC, TPO, TPS, TPU, TPV, or crosslinked olefinic thermoplastic elastomers, rubber-synthetic resin mixtures, PTFE, and / or combinations thereof. TPA represents thermoplastic polyamide elastomers, TPC (thermoplastic copolyester elastomers), TPO (olefinic thermoplastic elastomers), mainly PP / EPDM, TPS thermoplastic styrene block copolymers such as SBS, SEBS, SEPS, SEEPS, and MBS, TPU (urethane-based thermoplastic elastomers), or TPV (thermoplastic vulcanizates).

[0026] Preferably, the primary layer portion can be formed from an elastomer and the secondary layer portion can be formed from a thermoplastic resin, or the primary layer portion can be formed from a thermoplastic resin and the secondary layer portion can be formed from an elastomer. In the case of other layer portions, at least one polymer layer portion and at least one elastomer layer portion can be advantageous in the overall composite material. These combinations also have the effect of extending lifespan, optimizing wear or vibration, or optimizing conductivity.

[0027] Preferably, the insert member includes a reinforcing material in the form of a fiber, thread, cord or fabric formed from 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 their combinations. The reinforcing material can be added to achieve special properties of the primary layer portion and / or the secondary layer portion. Preferably, the reinforcing material is provided adjacent to the side surface of the first insert member. The reinforcing material can be provided only on the side surface of the first insert member. This can prevent or reduce local deformation of the insert member when in contact with a guided member (e.g., a rope).

[0028] Preferably, the secondary layer portion has a circular or elliptical cross-sectional shape. In other words, the geometric design of the secondary layer portion can further achieve and accurately realize the desired properties achieved by the secondary layer portion. For example, an elliptical cross-section can provide greater deformation resistance. Furthermore, a predetermined region in the cross-section of the insert member where a predetermined load (e.g., a bending motion) occurs can be particularly covered by the secondary layer portion to achieve locally desired properties.

[0029] Preferably, the primary layer and / or secondary layer have a conductivity of < 100 Ω × cm⁻¹. This means that at least one of the layers can be realized as a conductive layer. This allows for equipotentialization. As a result, copper brushes and the like that used in the prior art, which come into contact with the guided rope, can be eliminated, and the corresponding properties can be provided by the insert member. Furthermore, the primary layer and / or secondary layer can also be insulating. This is particularly advantageous when the signal is transmitted via a rope (e.g., a cableway). Such a signal can then be received by a signal pickup. An insulating insert member is advantageous for transmitting the signal via the rope without interference.

[0030] Preferably, the insert member includes a third layer which differs from the primary and / or secondary layers in terms of at least one material property. The third layer can be used in the insert member to achieve further properties. The same design options as for the primary and secondary layers are applied to the third layer. Furthermore, a fourth layer can also be provided. By using such a fourth layer which may differ from the primary, secondary, and / or tertiary layers in terms of at least one material property, the insert member can achieve further desired properties. Thus, a three-layer structure of the insert member can be provided. However, further layers can also be provided. For example, a fourth layer can be provided so that a four-layer structure of the insert member is realized. In total, a number of layers can be provided. Each layer can be individually designed to achieve desired properties of the insert member as a whole. In other words, each layer can have embodiments of the primary and / or secondary layers described herein.

[0031] Preferably, the secondary layer has noise-absorbing properties. For example, for cableway facilities in urban areas, minimizing facility downtime is particularly important. In urban areas, 24 / 7 operation is often taken for granted, meaning that environmental conditions differ from those in, for example, mountain applications. In other words, for example, with a service life of 30,000 km for guided ropes in urban use, insert members would need to be replaced several times a year, incurring considerable costs when replacing them. Furthermore, a higher requirement is demand for noise absorption. Therefore, the problem of noise emission can be addressed by providing a secondary layer that has noise-absorbing properties in particular. The secondary layer may include a softer material in contrast to the primary layer. The primary layer can be made of a harder or more wear-resistant material to ensure the required service life.

[0032] Preferably, the secondary layer can be designed as a weather-resistant cover layer. In the prior art, the weather-resistant layer of insert members typically affects other properties of the insert member, resulting in problems with durability and / or noise emission. In one embodiment of the present invention, only the secondary layer needs to be weather-resistant, and therefore the primary layer can be ensured to provide the other properties of the insert member. As a result, the insert member as a whole can have a longer service life.

[0033] Preferably, the secondary and primary layers are detachably connected to each other. If 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 worn, as the inner layer is still usable. In other words, by using an optimized core material, the core material can be used for a longer period than would normally be the case with a homogeneous insert lining. This means that the overall service life can be advantageously extended by applying a new cover layer. Recycling processing techniques allow for the reuse of various areas of the insert member. Separability between the primary and secondary layers can be provided, for example, by a separation layer. Furthermore, the secondary and primary layers can also be bonded to each other, and in the case of replacement, the layer to be removed can be removed, for example, by milling or turning. It is also conceivable that the secondary and primary layers are actively and / or inactively connected to each other. This makes replacement particularly easy.

[0034] Preferably, the secondary layer and / or primary layer have at least one cavity. The at least one cavity in the insert member can provide a favorable clamping force for the insert member on the rim.

[0035] Preferably, the primary layer has a larger radial extension than the secondary layer. In other words, the primary layer can be thicker radially or vertically than the secondary layer. As a result, when the primary layer is provided on the side of the first insert member and thus in contact with the guided rope or cable, a longer service life can be achieved. In this case, the secondary layer can have noise absorption or emission attenuation properties. It has been found that both objectives, namely emission reduction and increased durability, can be achieved.

[0036] Preferably, the insert member is designed as an annular insert member, and the ratio of the inner diameter to the outer diameter is preferably in the range of 0.3 to 0.9, particularly in the range of 0.7 to 0.85. The first range has been proven to be particularly advantageous when the insert member is used in cable cars in mountainous areas. The range of 0.7 to 0.85 has been proven to be particularly advantageous with respect to noise emission reduction, which is why such an insert member is particularly suitable for use in urban or noise-regulated areas.

[0037] Preferably, the primary layer has a radial extension in the range of 10% to 90%, preferably 20% to 80%, of the radial extension length of the secondary layer. In the first range, it has been found that only a very reduced proportion of the energy introduced into the insert member is converted into thermal energy, and the remainder is released again as kinetic energy. In this case, the secondary layer can be surrounded by the primary layer. In this case, the secondary layer can be arranged radially within the insert member. This allows the insert member to achieve dynamic properties when subjected to load in such a way that energy introduced into the system is released again, advantageously generating only a small amount of thermal energy. As a result, localized temperature peaks within the insert member can be avoided, thereby preventing thermal damage due to carbonization. Preferably, the thermal energy entering the insert member can be reduced or minimized by introducing the secondary layer across the entire width of the cross-section, particularly in the region subjected to dynamic stress below the contact point between the insert member and the guided member. In the second area, it was shown that the insert members have an increased service life, even under dynamic loads.

[0038] Preferably, the ratio of the extended length of the primary layer in the width direction to the extended length of the secondary layer in the width direction is in the range of 1.1 to 2.5. In other words, the secondary layer can be provided only partially in the width direction. This is particularly advantageous when the contact area between the insert member and the guided member is designed to be replaceable. In other words, the primary layer can remain, but the secondary layer, which is provided only partially in the width direction, is replaceable. In this way, an insert member that is at least partially recyclable and particularly environmentally friendly can be realized.

[0039] The above section primarily described the primary and secondary layers. However, further layers can also be provided. For example, a tertiary layer may have similar characteristics and / or design to the primary or secondary layers.

[0040] Amidst increasing demands for the use of sustainable products, the multilayer structure of insert components can contribute to the fact that fewer high-performance materials can be used along with the raw materials that must be used, thereby allowing for the use of more sustainable, and possibly less elastic, materials. Furthermore, the separation of recyclable and non-recyclable materials can be carried out efficiently and effectively. In addition, "green" raw materials can be used in multilayer insert components, making the recycling of insert components easier.

[0041] Although the above section mainly described a two-layer insert member, several layers (for example, three or more) may be provided.

[0042] A roller system is provided, particularly for cableway facilities and particularly for guiding ropes or cables, comprising a rim and an insert member as described in any one of the above embodiments, wherein the insert member is mounted on the rim so as to be rotatable with the rim.

[0043] A further aspect of the present invention provides a method for manufacturing an insert member, particularly for cableway facilities, and especially for guiding ropes or cables, comprising the steps of: providing a primary layer and a secondary layer that differ with respect to at least one material property; and joining the primary layer to the secondary layer by compression molding, injection molding, extrusion molding, casting, winding, printing, and / or vulcanization. Preferably, in the above method, the insert member is manufactured according to any one of the above embodiments. Preferably, the method further comprises the step of mechanically reworking the insert member by turning or milling.

[0044] The individual features of each embodiment can be combined with other features or other embodiments to form new embodiments. In this case, the embodiments and advantages mentioned in relation to each embodiment or feature can be similarly applied to the new embodiments. Furthermore, embodiments and advantages mentioned in relation to a device can be similarly applied to a method, and conversely, embodiments and advantages mentioned in relation to a method can be similarly applied to a device.

[0045] In the following, preferred embodiments will be described in detail with reference to the attached drawings. [Brief explanation of the drawing]

[0046] [Figure 1] This is a schematic perspective view of an insert member according to an embodiment of the present invention. [Figure 2] This is a schematic cross-sectional view passing through a portion of the insert member according to an embodiment of the present invention. [Figure 3a-3b] This is a schematic cross-sectional view of an insert member according to an embodiment of the present invention. [Figure 4a-4c] These are schematic cross-sectional views passing through the insert member according to the embodiment of the present invention. [Figure 5a-5b]It is a schematic cross-sectional view passing through an insert member according to an embodiment of the present invention. [Figure 6] It is a flowchart of a method for manufacturing an insert member according to an embodiment of the present invention.

Embodiments for Carrying out the Invention

[0047] Insert members are generally regarded as safety components and are subject to strict approval criteria. The typical maximum occurring and approved surface pressure in the profile is 6 N / mm 2 . Also, for high-load insert members, a surface pressure up to 9 N / mm 2 is permitted. For values exceeding this, up to 20 N / mm 2 and an impact on reducing the lifespan is expected. These operating conditions are tested using finite element simulations, dynamic tests on a test bench or on the system itself. The service life of the insert member is usually defined by the number of kilometers of the guided rope. However, there are also specifications indicating the operating time. The loads occurring here include the rope force, normal force, surface pressure, the shape dimensions of the rope and the insert member, the operating speed of the system, ambient conditions, tightening force / installation force, and the dimensions of the insert member. However, it also includes the material data / material properties of the insert member, as well as the service specification and the inspection specification. Despite all this, the insert member is a wearing part in a rope guide or rail guide, and wear and breakage due to a wide variety of causes are known.

[0048] Insert members are typically replaced due to wear or cracks that form on their surface. The standards specified by the system manufacturer or in the specifications apply here. Wear occurs when the material of the insert member, either within or on the ventral side of the "profile base," is removed by the relative movement between the insert member and the rope / rail, combined with "misalignment" or "tracking" of the rope on the insert member. Therefore, wear is measurable. Vibration, impact, or an inappropriate rope diameter can also lead to excessive wear. Cracks occur, for example, due to material aging or mechanical overload. Other causes include various types of breakout, material damage caused by oil and grease, ring slippage, cracks (also due to excessively tight press fitting to the pulley body), and breakout due to misaligned rope guides.

[0049] The latest conventional technologies use materials that strike a balance between target values ​​such as dynamic properties (heat generation), mechanical properties (wear resistance), conductivity, noise emission, friction, braking properties, and weather resistance. The composition of the mixtures and the current structure and shape dimensions of the insert components are sufficient for most applications to date.

[0050] Figure 1 is a perspective view of an insert member 1 according to an embodiment of the present invention. The insert member 1 has a first insert member side surface 4 and an insert member side surface 6 on the opposite side. In addition, the member of this embodiment is designed as a ring-shaped insert member and is designed to rotate around a rotation axis D. Furthermore, the insert member 1 has a geometric shape portion 7 on the first insert member side surface 4. The geometric shape portion corresponds to the shape of the guided member in cross-section. In this embodiment, a rope (not shown in Figure 1) is guided through the insert member. The geometric shape portion 7 is designed by the guided rope.

[0051] Figure 2 is a cross-sectional view passing through the insert member of Figure 1. More precisely, the insert member 1 of Figure 1, together with the rim 10, forms the roller system 100 according to an embodiment of the present invention. Furthermore, a guided member 8, in this case a cord, is shown in cross-section. The cable 8 rests on the geometrically shaped portion 7 of the insert member 1. In the embodiment shown in Figure 2, the guide direction extends into the plane of the paper.

[0052] Figure 3a is a cross-sectional view passing through an insert member 1 of one embodiment of the present invention. The insert member 1 has a primary layer 2 and a secondary layer 3. The primary layer 2 and the secondary layer 3 differ from each other with respect to at least one material property. Furthermore, a geometric shape portion 7, which is designed to contact and guide the rope, can be shown on the side surface 4 of the first insert member. Also shown are the radial or vertical direction R and the width direction B. The secondary layer is provided only in the region of the geometric shape portion 7, in the width direction B. In this embodiment, the secondary layer has a dynamically optimized material that, as a result of the load, introduces a very small amount of thermal energy into the insert member. More precisely, the secondary layer 3 is designed in such a way that a slight rolling action occurs, which can significantly reduce the thermal energy introduced into the insert member 1. Due to the material design, the dynamically introduced energy is released again. This means that, because there is little to no thermal energy introduced into the insert member by the pressure of the rope, thermal damage by carbonization in the radial direction can be avoided somewhat below the geometric shape 7. Furthermore, the insert member of this embodiment has a reinforced inner layer 9 that is designed to contact the rim. This allows the insert member 1 to be fixed to the rim particularly securely.

[0053] Figure 3b is a schematic cross-sectional view passing through the insert member 1 of a further embodiment of the present invention. The difference from the embodiment shown in Figure 3a is that the secondary layer 3 extends across the entire width of the insert member 1. As a result, the effects of the above-described embodiment can be achieved across the entire width of the insert member 1 in the width direction B. This is particularly advantageous when the precise contact points between the insert member 1 and the guided member are not predetermined. Another advantage of this structure is the easier introduction of the secondary layer in the lining manufacturing process.

[0054] Figure 4a is a schematic cross-sectional view passing through the insert member 1 of one embodiment of the present invention. In the embodiment shown in Figure 4a, mechanical optimization of the insert member 1 is achieved at the interface with the rope. As a result, wear and breakout behavior of the cover layer can be significantly reduced. Depending on the manufacturing process, there are various options for positioning the mechanically optimized cover layer. In Figure 4a, the secondary layer 3 is located at the rope base of the geometric shape portion 7. Due to the shape dimensions of the rope and lining, the greatest load may occur at the rope base, which means that the maximum service life extension can be achieved here, in particular by providing a resistant material.

[0055] Figure 4b shows a further embodiment of the present invention in which a wear-resistant secondary layer 3 is provided over the entire outer region of the insert member. This is particularly advantageous when other contact surfaces may occur outside the geometric shape portion 7. Furthermore, the secondary layer 3 can be weather-resistant, which means that the insert member can have an extended service life even under adverse weather conditions.

[0056] In Figure 4c, the secondary layer 3 is provided as a mechanically reinforced or wear-resistant layer, serving as a lining for the geometric shape portion 7.

[0057] Overall, in all embodiments shown in Figures 4a to 4c, the contact surface between the rope and the insert member is lined with a wear-resistant secondary layer 3.

[0058] Figure 5a shows a further insert member 1 of a further embodiment of the present invention. In this embodiment, the insert member 1 includes an optimized conductive secondary layer 3 throughout the outer region (i.e., the side surface 4 of the first insert member). This enables favorable signal transmission behavior of the insert member 1. Furthermore, the primary layer 2 of this embodiment has improved dynamic strength.

[0059] Similarly, the secondary layer 3 can also provide the desired insulation.

[0060] Figure 5b shows a further embodiment of the present invention in which the secondary layer 3 can be updated in a simple manner. Here, for example, it is sufficient that only the area surrounding or adjacent to the geometric shape portion 7 of the secondary layer is updated. Alternatively, the entire portion of the insert member facing the side surface of the first insert member may be updated.

[0061] Figure 6 is a flowchart illustrating the procedure for manufacturing an insert member according to one embodiment of the present invention. In step S1, a primary layer 2 and a secondary layer 3 are provided, each differing in at least one material property. In step S2, the primary layer 2 and the secondary layer 3 are joined together by compression molding, injection molding, extrusion molding, casting, winding molding, printing, and / or vulcanization molding.

[0062] Step S3 is an optional step that includes mechanical refinishing of the insert member by turning or milling. [Explanation of Symbols]

[0063] 1 Insert Member 2 Primary layer part 3 Secondary layer part 4. Side view of the first insert member 6. Side view of the second insert member 7 Geometric shape section 8 Guided members 9. Reinforced inner layer 10 rim 100 Roller System D Rotation axis R Radial direction B Width direction

Claims

1. An insert member (1) specifically for cableway facilities, and more particularly for guiding ropes or cables, Primary layer (2), The secondary layer (3) provided in and / or on the primary layer (2), Includes, The insert member (1) has a first insert member side (4) designed to contact a member (8), particularly a rope or cable, that is guided in the guiding direction, particularly in the circumferential direction, and a second insert member side (6) opposite to the first insert member side (4). The primary layer (2) and the secondary layer (3) differ with respect to at least one material property, The insert member (1) has a substantially constant cross-section along the guide direction, The insert member (1) extends in the radial direction (R) and the width direction (B) in the cross-section, which are perpendicular to the guide direction and perpendicular to each other. Insert member (1).

2. The insert member (1) according to claim 1, wherein the primary layer (2) and the secondary layer (3) are each formed as elastomer layers.

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

4. The insert member (1) according to any one of claims 1 to 3, wherein the at least one material property includes wear resistance, heat generation, conductivity, noise damping properties, vibration damping properties, friction coefficient, weather resistance, and / or thermal conductivity.

5. The insert member (1) according to any one of claims 1 to 4, further comprising a core layer disposed on the side surface (6) of the second insert member, wherein the core layer differs from the primary layer (2) and / or the secondary layer (3) with respect to at least one material property.

6. The insert member (1) according to any one of claims 1 to 5, wherein the secondary layer (3) extends at least partially in the width direction (B) in cross-section.

7. The insert member (1) according to any one of claims 1 to 6, having a geometrically shaped portion (7) for receiving and guiding the member (8), particularly the rope or cable.

8. The insert member (1) according to claim 7, wherein the secondary layer (3) extends in the width direction (B) only in the region of the geometric shape (7) in the cross-section.

9. The insert member (1) according to claim 7 or 8, wherein the secondary layer portion (3) is disposed adjacent to the geometric shape portion (7) in cross-section.

10. The insert member (1) according to any one of claims 7 to 9, wherein the secondary layer portion (3) is provided at a lower point of the geometric shape portion (7).

11. The insert member (1) according to any one of claims 1 to 10, wherein the secondary layer (3) extends at least partially in the radial direction (R) in cross-section.

12. The insert member (1) according to any one of claims 1 to 11, further comprising a fiber-reinforced inner layer (9) disposed on the side surface (6) of the second insert member.

13. The insert member (1) according to any one of claims 1 to 12, wherein the primary layer (2) and / or the secondary layer (3) comprises at least one elastomer and / or thermoplastic resin 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. The insert member (1) according to any one of claims 1 to 13, wherein the primary layer (2) and / or the secondary layer (3) include TPA, TPC, TPO, TPS, TPU, TPV, or a crosslinked olefin thermoplastic elastomer, a rubber / synthetic resin mixture, PTFE, and / or a combination thereof.

15. The insert member (1) according to any one of claims 1 to 14, wherein the primary layer (2) is formed of an elastomer and the secondary layer (3) is formed of a thermoplastic resin, or the primary layer (2) is formed of a thermoplastic resin and the secondary layer (2) is formed of an elastomer.

16. The insert member (1) according to any one of claims 1 to 15, wherein the secondary layer (3) has a circular or elliptical cross-sectional shape.

17. The insert member (1) according to any one of claims 1 to 16, comprising reinforcing materials in the form of fibers, filaments, cords, or fabrics of glass, carbon, rock wool, metal wool, titanates, aluminosilicates and aluminum oxides, ceramics, silicon carbides, iron and copper, and their alloys, polyamides, polyacrylonitriles, polyesters, phenols, aramids, cotton, cellulose and / or combinations thereof.

18. The insert member (1) according to any one of claims 1 to 17, wherein the secondary layer (3) has a circular or elliptical cross-sectional shape.

19. The insert member (1) according to any one of claims 1 to 18, wherein the primary layer (2) and / or the secondary layer (3) have an conductivity of < 100 Ω × cm.

20. The insert member (1) according to any one of claims 1 to 19, further comprising a tertiary layer which is different with respect to at least one material property from the primary layer (2) and / or the secondary layer (3).

21. The insert member (1) according to any one of claims 1 to 20, wherein the secondary layer (3) has noise-absorbing properties.

22. The insert member (1) according to any one of claims 1 to 21, wherein the secondary layer (3) is designed as a weather-resistant cover layer.

23. The insert member (1) according to any one of claims 1 to 22, wherein the secondary layer (3) and the primary layer (2) are detachably connected to each other.

24. The insert member (1) according to any one of claims 1 to 23, wherein the secondary layer (3) and / or the primary layer (2) have at least one cavity.

25. The insert member (1) according to any one of claims 1 to 24, wherein the primary layer (2) has a larger extension in the radial direction (R) than the secondary layer (3).

26. The insert member (1) according to any one of claims 1 to 25, which is designed as an annular insert member (1), wherein the ratio of the inner diameter to the outer diameter is preferably in the range of 0.3 to 0.9, and more particularly in the range of 0.7 to 0.

85.

27. The insert member (1) according to any one of claims 1 to 26, wherein the primary layer (2) has a radial extension length (R) in the range of 10% to 90%, preferably 20% to 80%, of the radial extension length (R) of the secondary layer (3).

28. The insert member (1) according to any one of claims 1 to 27, wherein the ratio of the extended length of the primary layer (2) in the width direction (B) to the extended length of the secondary layer (3) in the width direction (B) is in the range of 1.1 to 2.

5.

29. A roller system (100) particularly for cableway facilities, and especially for guiding ropes or cables, Rim (10) and, An insert member (1) according to any one of claims 1 to 28, A roller system (100) comprising the insert member (1) being attached to the rim (10) in such a manner that the insert member (1) can rotate together with the rim (10).

30. A method for manufacturing an insert member (1) particularly for cableway facilities, and especially for guiding ropes or cables, A step of providing a primary layer (2) and a secondary layer (3) that differ in at least one material property, A step of joining the primary layer (2) to the secondary layer (3) by compression molding, injection molding, extrusion molding, casting, winding molding, printing, and / or vulcanization molding, A method that includes this.

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