Fastening system for a conveyor belt

Abstract

A fastening system (210) for joining two opposing ends of flexible conveyor belt segments (201, 202) includes mating sets of shaped connectors (230) extending from confronting ends of flexible conveyor belt segments. The shaped connectors include parallel, laterally-extending openings. The shaped connectors interlock with each other to resist longitudinal tension and to align the openings into two passageways, which each receives a prong of a dual-pronged locking device (250) to secure the ends together.

Description

[0001] FASTENING SYSTEM FOR A CONVEYOR BELT

[0002] RELATED APPLICATIONS

[0003] The present application claims priority to US Provisional Patent Application No. 63 / 653,473, filed May 30, 2024 and entitled "Fastening System for a Conveyor Belt", the contents of which are herein incorporated by reference.

[0004] BACKGROUND OF THE INVENTION

[0005] The present invention relates generally to power-driven conveyor belts, and more particularly, to a system and method for connecting ends of a conveyor belt body to form an endless conveyor belt.

[0006] Low tension, direct drive conveyor belts are typically used in situations where hygiene and cleanliness are important. For example, in food processing plants such as those that process meat products for human consumption, low tension, direct drive conveyor belts are used to transport items. Sanitation is important and, therefore, the endless belts used in such conveyors are conventionally made of materials that can be hygienically cleaned, such as thermoplastics or stainless steel.

[0007] An example of a flexible endless belt suitable for implementing an illustrative embodiment of the invention is shown in FIG. 1. An endless conveyor belt 10 in a typical installation moves around two sprockets 12 and 14, drums or pulleys. A first sprocket 12 may be a drive sprocket for driving the conveyor belt, while the second sprocket may be an idle or slave sprocket 14. The belt 10 has an outer surface 110 serving as an article-conveying surface and an inner surface 22 serving as a drive surface. The inner surface 22 includes drive elements, illustrated as teeth 26, preferably spaced equidistantly from each other along the inner driven surface 22. The teeth 26 engage grooves or other suitable structure, spaced around the circumference of the sprockets 12, 14 to move the belt. The upper span of the belt will travel in the direction of arrow 15. The flexible belt 10 wraps around the sprocket and around a return roller, or shoe or drum, in the return path.

[0008] The belt is made of a resilient material, such as a thermoplastic polymer, an elastomer, or a rubber, and is flexible along its length. Examples of such flexible endless belts include the THERMODRIVE series of belts available from Intralox, L.L.C, of Harahan, LA, the Super Drive™, and other positive drive belts available from Volta Belting Technology, the Cleandrive product line available from Habasit and other flexible, positive drive conveyor belts known in the art.

[0009] A flexible endless belt is normally formed by joining two ends of the belt together at a seam 120. Methods of joining two ends of the belts together include splicing, whereby splicing presses are used to weld the butt ends of the conveyor belt sections together, mechanical means, such as a hinge-pin system and / or a knuckled connector system described in US Patents and 8,002,110 and 8,695,790, the contents of which are incorporated herein by reference.

[0010] The belt may have to be removed from the sprockets for maintenance of the system, for cleaning, or for repair. Removing the endless belt 10 of FIG. 1 poses an inconvenience, normally requiring disassembly of the conveyor frame, movement of the sprockets, and possibly destruction of the belt (or at least cutting the belt to be re-seamed later).

[0011] SUMMARY OF THE INVENTION

[0012] The present invention provides a fastening system for a flexible conveyor belt. The fastening system includes mating sets of shaped, rigid connectors extending from confronting ends of flexible conveyor belt segments. The rigid connectors include parallel, laterally-extending openings. The rigid connectors interlock with each other to resist longitudinal tension and to align the openings into two passageways, which each receives a prong of a dual-pronged locking device to secure the ends together.

[0013] According to one aspect, a fastening system for fastening a first end of a flexible conveyor belt segment to a second end of a flexible conveyor belt segment comprises a first rigid connector, a second rigid connector, a third rigid connector, and a locking device. The first rigid connector extends from the first end and has sidewalls that are angled relative to a direction of belt travel. The first rigid connector includes a first inner lateral opening and a first outer lateral opening. The second rigid connector extends from the first end and is separated from the first rigid connector by a first hollow. The second rigid connector has sidewalls that are angled relative to a direction of belt travel and includes a second inner lateral opening aligned with the first inner lateral opening and a second outer lateral opening aligned with the first outer lateral opening. The third rigid connector extends from the second end and is configured to be received by the first hollow. The third rigid connector has sidewalls that are angled relative to a direction of belt travel and includes a third inner lateral opening that aligns with the first and second outer lateral openings and a third outer lateral opening that aligns with the first and second inner lateral openings. The locking device includes a first prong inserted through the first inner lateral passageway, second inner lateral opening and third outer lateral opening and a second prong inserted through the first outer lateral opening, second outer lateral opening and third inner lateral opening.

[0014] According to another aspect, a connector in a fastening system for a conveyor belt extends from an end of a belt segment and comprises a body tapering in width from a base to a tip and including sidewalls angled relative to a direction of conveyor belt travel. A first laterally-extending opening extends through the body at the base and a second laterally- extending opening extends through the body at the tip.

[0015] BRIEF DESCRIPTION OF THE DRAWINGS

[0016] These features of the invention, as well as its advantages, are better understood by referring to the following description, appended claims, and accompanying drawings, in which:

[0017] FIG. 1 illustrates an endless conveyor belt of the prior art;

[0018] FIG. 2 is an isometric top view of a fastening system for an endless conveyor belt according to an embodiment;

[0019] FIG. 3 is a bottom view of the fastening system of FIG. 2;

[0020] FIG. 4 is cross-sectional side view of the fastening system of FIG. 2;

[0021] FIG. 5 is an isometric top view of one section of the fastening system of FIG. 2;

[0022] FIG. 6 is a bottom view of the section of FIG. 5;

[0023] FIG. 7 is a sectional view through lines A- A of FIG. 4;

[0024] FIG. 8 is a sectional view of one section of the fastening system of FIG. 7;

[0025] FIG. 9 is a detailed top view of an edge portion of the fastening system of FIG. 2;

[0026] FIG. 10 is a detailed bottom view of the edge portion of FIG. 9;

[0027] FIG. 11 is a bottom view of a second edge portion of the fastening system of FIG. 2;

[0028] FIG. 12 is a top view of the second edge portion of FIG. 11;

[0029] FIG. 13 is a detailed view of an edge of the fastening system of FIG. 2 during insertion of a locking device;

[0030] FIG. 14 shows the edge of FIG. 13 as the locking device is locked into place; FIG. 15 is a top view of an edge portion of a fastening system including a locking device with locking bumps;

[0031] FIG. 16 is a bottom view of the edge portion of FIG. 15;

[0032] FIG. 17 is a bottom view of an edge portion of a fastening system including a locking device with an enlarged base;

[0033] FIG. 18 is a bottom view of an edge portion of a fastening system including a locking device with a side locking protrusion;

[0034] FIG. 19 is an isometric top view of a fastening system for a conveyor belt according to another embodiment;

[0035] FIG. 20 is a cross-sectional side view of the fastening system of FIG. 19;

[0036] FIG. 21 is a top view of a section of the fastening system of FIG. 19;

[0037] FIG. 22 is a bottom view of the section of FIG. 21;

[0038] FIG. 23 is a side view of the section of FIG. 21;

[0039] FIG. 24 is a top view of a rigid link of the fastening system of FIG. 19;

[0040] FIG. 25 is a bottom view of the rigid link of FIG. 24;

[0041] FIG. 26 is an isometric top view of the rigid link of FIG. 24;

[0042] FIG. 27 is an isometric bottom view of the rigid link of FIG; 24;

[0043] FIG. 28 is a sectional view through lines A- A of FIG. 20;

[0044] FIG. 29 is a detailed view of portion B of FIG. 28;

[0045] FIG. 30 is an isometric view of the fastening system of FIG. 19 during mating;

[0046] FIG. 31 is an isometric view of the fastening system of FIG. 30, as the rigid connectors snap into engagement;

[0047] FIG. 32 shows the fastening system of FIG. 31 prior to insertion of a locking device;

[0048] FIG. 33 is a side view of the fastening system of FIG. 19 during an alternative approach to mating the rigid links;

[0049] FIG. 34 shows the fastening system of FIG. 33 during mating;

[0050] FIG. 35 is an isometric view of a rigid connector for a fastening system according to another embodiment.

[0051] FIG. 36 is an isometric top view of a fastening system for an endless conveyor belt according to an embodiment;

[0052] FIG. 37 is a bottom view of the fastening system of FIG. 36;

[0053] FIG. 38 is a top view of one section of the fastening system of FIG. 36; FIG. 39 is a bottom view of the section of FIG. 38;

[0054] FIG. 40 is a detailed top view of an edge portion of the section of FIG. 38;

[0055] FIG. 41 is a detailed bottom view of the edge portion of FIG. 40;

[0056] FIG. 42 is a detailed bottom view of a middle portion of the section of FIG. 38;

[0057] FIG. 43 is a detailed top view of the middle portion of FIG. 40;

[0058] FIG. 44 is an isometric bottom view of a fastening system for an endless conveyor belt according to another embodiment;

[0059] FIG. 45 is a side view of another embodiment of a fastening system for a conveyor belt;

[0060] FIG. 46 is a side view of the embodiment of FIG. 45 illustrating the lines used to fasten the mating segments of the fastening system together.

[0061] FIG. 47 is an isometric top view of a portion of a fastening system for a conveyor belt according to another embodiment;

[0062] FIG. 48 shows the portion of FIG. 47 with the connectors separated;

[0063] FIG. 49 is a top view of the fastening system of FIG. 47;

[0064] FIG. 50 is a detailed first side view of a connector of the fastening system of FIG. 47;

[0065] FIG. 51 is a detailed second side view of the connector of FIG. 50;

[0066] FIG. 52 is a first view of an edge link of a fastening system according to an embodiment;

[0067] FIG. 53 is a second view of the edge link of FIG. 52;

[0068] FIG. 54 is a first view of an edge of a fastening system including two edge links;

[0069] FIG. 55 is a second view of the edge of FIG. 54;

[0070] FIG. 56 shows the edge of FIG. 55 with locking device seated therein;

[0071] FIG. 57 is an isometric view of a fastening system with shaped, stepped connectors according to another embodiment;

[0072] FIG. 58 is a detailed view of portion A of the fastening system of FIG. 57;

[0073] FIG. 59 is a top view of the fastening system of FIG. 57;

[0074] FIG. 60 is a detailed view of portion B of FIG. 59;

[0075] FIG. 61 is a detailed view of portion C of FIG. 59;

[0076] FIG. 62 is an isometric view of a single connector of the fastening system of FIG. 57;

[0077] FIG. 63 is another view of the single connector of FIG. 62;

[0078] FIG. 64 is a side view of the fastening system of FIG. 57; FIG. 65 is a bottom view of the fastening system of FIG. 57;

[0079] FIG. 66 is a detailed view of an edge portion D of the fastening system of FIG. 65;

[0080] FIG. 67 is a cross-sectional view of an edge portion of the fastening system of FIG. 57;

[0081] FIG. 68 is a top view of the edge portion of FIG. 67; and

[0082] FIG. 69 is an isometric view of the end portion of FIG. 67.

[0083] DETAILED DESCRIPTION OF THE INVENTION

[0084] The present invention provides a fastening system for facilitating assembly and disassembly of a conveyor belt. The present invention will be described below relative to an illustrative embodiment. Those skilled in the art will appreciate that the present invention may be implemented in a number of different applications and embodiments and is not specifically limited in its application to the particular embodiments depicted herein.

[0085] FIGS. 2—4 illustrate a fastening 210 for a conveyor belt according to an illustrative embodiment of the invention. The fastening system fastens two ends of one or more belt segments 201, 202 together at a seam 203 to form an endless conveyor belt or a portion of an endless conveyor belt. The illustrative seam 203 is halfway between two drive elements, shown as drive bars 206, but the invention is not so limited. The fastening system may fasten the ends of a single, elongated belt segment to form an endless conveyor belt, or fasten successive segments together. A locking mechanism 250 secures the two ends together. The illustrative locking mechanism 250 comprises two prongs joined at a base that extend through linking passageways formed by interlocked connectors extending from mating ends of the belt segments 201, 202, as described in detail below, but alternative locking mechanisms may be used. Each illustrative belt segment 201, 202 is identical to each other, but the invention is not so limited.

[0086] Each illustrative belt segment 201, 202, shown in FIGS. 5—6, comprises a flexible belt body that extends longitudinally from a mating end 205 to an opposite second end 208 and laterally from a first side 214 to a second side 215. The body of each belt segment 201, 202 extends in thickness from an outer surface 216, illustrated as a conveying surface for conveying a product, to an inner surface 217. The inner surface may be a drive surface including drive elements, illustrated as teeth 206, extending therefrom. The drive elements engage sprockets, such as the sprocket 12 shown in FIG. 1, or drums that drive or guide the conveyor belt. The longitudinal direction L is the direction of belt travel when a conveyor belt comprising the fastening system 210 is implemented in a conveyor system. The teeth 206 are spaced longitudinally on the inner surface 217 by a distance defined as a belt pitch. Other suitable driving means may be used, and the invention is not limited to drive teeth that engage a sprocket.

[0087] An endless conveyor belt may comprise a plurality of belt segments joined together, in which case the outer ends 208 are themselves fastened to another belt segment, using rigid connectors as described below or another suitable means, or a single belt segment having ends joined together using the fastening system 210 to form an endless belt.

[0088] The conveyor belt segments 201, 202 and resulting conveyor belt can be formed of any suitable material, such as a thermoplastic polymer, an elastomer, or a rubber, and is preferably flexible about both longitudinally and laterally, so that the resulting conveyor belt is capable of forming a trough. The conveyor belt can be made from any of a number of methods, e.g., milling, extrusion, and / or injection molding. The illustrative belt segments are formed of a flexible material with a modulus of elasticity that ranges between about 0.02 GPa to about 0.3 GPa.

[0089] Each flexible belt segment 201, 202 includes a set of laterally spaced apart rigid connectors 230 extending from the inner, mating end 205. The set of rigid connectors 230 is arranged to mate with a corresponding set of laterally spaced apart rigid connectors 230 extending from the inner, mating end of the opposing belt segment to join the belt segment ends together. The illustrative sets of rigid connectors 230 are formed of a relatively stiffer material that has a modulus of elasticity that is between about 2 and about 50 times that of the flexible material forming the bodies of the belt segments 201, 202, but less than about 4 GPa. In one embodiment, the rigid connectors are formed of polyurethane grades (including polyethers and polyesters). In an embodiment that rigid material has high hardphase to softphase ratios. The stiffer material increases load capacity, minimizes distortion, and facilitates insertion of a locking device by potentially reducing friction, in addition to providing a compact seam.

[0090] In one embodiment, rigid connectors also extend from the outer end 208 to join that end to another flexible belt segment.

[0091] The rigid connectors 230 are anchored in the flexible belt segments 201, 202 with the mating portions extending from the mating ends 205 of the flexible belt segments 201, 202. In one embodiment, the rigid connectors 230 are embedded or otherwise attached to the flexible belt segments through an adhesive, mechanical bond, overmolding processes or other suitable means. An anchor 207, shown in FIG. 4, may be used to embed one or more rigid connectors in the corresponding belt segment. In another embodiment, the rigid connectors are welded or otherwise connected to the ends of the flexible belt segments.

[0092] In one embodiment, the rigid connectors 230 comprises a series of rigid links separated by hollows 231. As shown in FIGS. 7—8, each link 230, as described below, includes sidewalls that are angled relative to the direction of belt travel, so that the link tapers in width from a base to a tip to form hollows that widens from the base to tip. Each link 230 wedges into a hollow 231 formed between two links on the other set of rigid connectors to interlock the segments together. The tapering shape allows the links to snap-fit together and resist longitudinal tension prior to insertion of the locking device 250, as well as align the locking passageways formed by the interlocked connectors. The top surface of the rigid connectors aligns with the top surface 216 of the flexible belt segment. The bottom surface of the rigid connectors may align with or be inset from the bottom surface of the flexible belt segment, so that the linking portion is within the body of the conveyor belt, but the invention is not so limited.

[0093] Each link 230 includes two longitudinally-spaced apart, laterally-extending openings 240, 241 that are parallel to each other. As shown in FIG. 7, inner openings 240 of a first segment align with outer openings 241 of the opposing segment to form a laterally- extending locking passageway for receiving a prong of the locking device 250 to secure the two segments together. The illustrative locking device 250 comprises two parallel prongs extending from a base and including tapered tips 252 to facilitate advancement of the prongs through the passageways. The locking device 250 is also formed of a rigid material, preferably metal. The use of two connected prongs prevents rotation of a prong within a passageway, reduces tenting, facilitates insertion and removal of the locking device, and facilitates scraping of the conveyor belt.

[0094] The links 230 can all be joined together on a single base, multiple links can extend from a shared base, or each link can be individually connected to the body of a corresponding flexible belt segment 201, 202.

[0095] In one embodiment, the rigid connectors may be embedded within a separate or intermediate belt segment adapted to be spliced or otherwise connected to an end of a conveyor belt segment. Alternatively, rigid connectors may be embedded, welded, or adhered directly to an end of a conveyor belt, individually or as a grouped set. In another embodiment, a conveyor belt may be formed by joining a series of flexible conveyor belt segments with embedded rigid connectors extending from each end in a modular format.

[0096] The belt segments may include a latch for securing the locking device 250 in a locked position. For example, in one embodiment, a latch is formed at the side edges of the belt segment at the mating end 205 by rigid latching connectors 260, 270 at each side edge of a segment. As shown in FIGS. 9 — 10, a first latching connector 260 formed at side edge 215 includes a latching seat 261 on a bottom side for seating the base or another portion of the locking device 250. The illustrative first latching connector 260 is wider in the lateral direction than the intermediate rigid connectors 230 and shorter in length in the longitudinal direction than the intermediate rigid connectors 230. In one embodiment, the first latching connector 260 has a length that is about half that of the intermediate rigid connectors 230. The first latching connector 260 includes an inner passageway 263 that is open to the side edge, intersects the latching seat 261 and aligns with the inner passageway 240 of the intermediate rigid connectors 230. The first latching connector 260 includes a solid top 266. The seat 261 on the bottom side of the first latching connector 260 includes an opening 264 at the front edge and a lateral protrusion 265, which may be shaped to cradle a prong of the locking device 250.

[0097] FIGS. 11 and 12 show the second latching connector 270 at the second side edge 214. The second latching connector includes a latching seat 271 on a bottom side for seating the base or another portion of the locking device 250. The illustrative second latching connector 270 is wider in the lateral direction than the first latching connector 260. An outer portion of the second latching connector 270 is shorter in length than the rigid latching connectors and equal in length to the first latching connector 260. An inner portion of the second latching connector protrudes farther than the outer portion and includes both an outer passageway 272 and an inner passageway 273 that align with the outer and inner passageways 241, 240 of the intermediate rigid connectors 230. The inner passageway 273 is open to the side edge and intersects the seat 271. The second latching connector 270 includes a solid top 276. The seat 271 on the bottom side of the second latching connector 270 includes an opening 274 at the front edge and a lateral protrusion 275, which may be shaped to cradle a prong of the locking device 250. FIGS. 13 — 14 show the process of latching the locking device 250 after interlacing the rigid connectors 230 and latching connectors 260, 270 to secure two flexible belt segments 201, 202 together. In the interlaced position, the front openings of the latching connectors 264, 274 abut each other to form an enlarged seat formed by seats 261, 271. The prongs 252 of the locking device 250 are inserted through the openings 263, 273 and into passageways 272, 240, 241. As the base of the locking device 250 approaches the edge, it can be lifted into the seats 261, 271, which secure the locking device 250 in the latched portion. In the latched position, shown in FIG. 14, the base of the locking device 250 spans the front openings 264, 274 and is contained by the side edges of the seats 261, 271 and lateral protrusions 265, 275.

[0098] In one embodiment, the locking device 250 may comprise opposing and flipped-in- orientation J-shaped hooks, each including a longer prong and a shorter prong. The base of each hook is latched into an edge of the fastening system 210, while each prong extends through a portion of each passageway formed by the openings in the links, with a shorter prong of a first hook abutting a longer prong of the other hook within a passageway.

[0099] The latching mechanism is not limited to the illustrative embodiment. For example, as shown in FIG. 15 and 16, a locking device 280 may include an enlarged latching portion 281 including an intermediate bar inset from and parallel to the base and side protrusions to facilitate locking of the base in the latching connectors 260, 270.

[0100] In another embodiment, shown in FIG. 17, a locking device 290 includes an enlarged base with rounded protrusions.

[0101] In another embodiment, a locking device 291 includes a side protrusion 292 for latching the locking device to a latching connector 260, as shown in FIG. 18.

[0102] In another embodiment, the rigid connectors of a fastening system are shaped and include windows to the passageways to visualize the prongs of a locking device inserted therein. FIGS. 19 and 20 show a section of a fastening system 310 including tapering, rigid links 330 that interlock to join two flexible belt segments 301, 302 and are secured together with a dual-pronged locking device 350. A latch, as described above, may secure the locking device in a locked position.

[0103] FIGS. 21—23 show a flexible conveyor belt segment 301, 302 including a series of shaped rigid links 330 extending from a mating end 305 of the segment for mating with a corresponding flexible conveyor belt segment 301, 302 including shaped rigid links that interlace with the shaped rigid links 330. The shaped rigid links 330 taper from a base to a tip and are separated by correspondingly shaped hollows 331. Each link 330 includes two longitudinally-spaced apart, laterally-extending, parallel openings 340, 341 for receiving a prong of a locking device.

[0104] As shown in FIG. 23, a top surface 312 of the shaped rigid connectors 330 aligns with the top surface 316 of the flexible belt segment 301, 302. The bottom surface 338 of the shaped rigid connectors 330 aligns with the bottom surface 317 of the flexible belt segment, so that the linking portion is coplanar with the body of the conveyor belt. An anchor 307 may be used to embed one or more shaped rigid connectors 330 in the corresponding belt segment 301, 302. In another embodiment, the shaped rigid connectors 330 are welded or otherwise connected to the ends of the flexible belt segments.

[0105] FIGS. 24—27 show an individual shaped rigid link 330 in detail. Each link 330 includes a base 332 extending in thickness from a top surface that aligns with the top surface 316 of the associated flexible belt segment to a bottom surface that aligns with the bottom surface 317 of the associated flexible belt segment, so that the base is coplanar with the belt segment. The anchor 307 extends rearward from the base 332. The anchor 307 can have a tail, protrusions and— or openings to facilitate embedding of the anchor 307 in the flexible belt segment 301.

[0106] A body forming a linking section extends forward from the base and terminates in a rounded tip 333. The linking section top and bottom surfaces may also be coplanar with the base 332 and belt segment 301. The linking section of a link 330 tapers in width from the base 332 to tip 333 to form hollows that widens from a base to tip. Each linking section includes skewed sidewalls 335, 336 that extend at an angle of between about 5° and about 103relative to the longitudinal direction of travel. The tip 333 includes bulges 334 configured to be received in divots formed in the angled sidewalls 335, 336 around the inner laterally- extending opening 340 formed in a mating series of rigid shaped links. The bulge 334 surrounds the outer laterally-extending opening 341. FIGS. 28 and 29 show the interference fit between the rigid links 330 of opposing belt segment ends, including the engagement between the bulges 334 and divots at the inner laterally-extending opening 340. The illustrative configuration provides a snap-fit connection that resists longitudinal tension prior as well as provides a self-alignment of the locking passageways 340, 341, both vertically and longitudinally, to facilitate insertion of the prongs 352 of the locking device 350. The shaped rigid link 330 includes windows to the laterally-extending openings 340, 341 to facilitate visualization of the prongs of the locking device 350. The windows provide a line of sight to each prong across the width of the seam and also provides access for cleaning. Each lateral opening 340, 341 comprises a series of open saddles, alternating in orientation and forming the windows to the top or bottom surface of the rigid link. The illustrative inner opening 340 includes two downwards-facing saddles 342, 344 at side edges and an upwards-facing saddle 343 in the lateral middle of the opening 340. The illustrative downwards-facing saddles 342, 344 include walls that are angled so that the downwards- facing saddles 342, 344 angled towards the base 332 from the seat of the saddle to the bottom. The upwards-facing saddle 343 may also be angled. The illustrative outer opening 341 also includes downwards-facing edge saddles 345, 346, which may also be angled, and a middle upwards-facing saddle 347 that is open to the top of the link 330 and can also be angled. The windows are not limited to the illustrative direction, and any of the windows may open to either the top or bottom of the segment.

[0107] FIGS. 30, 31 and 32 show a process of mating the two belt segments 301, 302 prior to insertion of the locking device 350. The belt segments can be joined by angling the belt segments relative to each other, as shown in FIG. 30, then interweaving the rigid links 330 and hollows 331. Then, the segments 301, 302 are rotated relative to each other to snap the rigid links 330 into locking engagement, with the segments 301, 302 parallel to each other and forming two passageways 340, 341 for receiving the prongs of the locking device.

[0108] Alternatively, as shown in FIGS. 33 and 34, two belt segments 301, 302 can be joined together by vertically aligning each rigid link 330 with a corresponding hollow 331, then snapping the two sets of rigid links 330 together.

[0109] In another embodiment, shown in FIG. 35, a set of shaped, rigid links 430 configured to extend from a flexible belt segment, such as described above, may comprise a rigid base material overmolded with a flexible material. The flexible material fills recesses 435 formed in the rigid base material to increase the flexibility of the rigid links 430 between the openings 440, 441 while retaining strength. Other means for promoting flexibility within the rigid links may be used.

[0110] FIG. 36 and 37 show an embodiment of a fastening system 510 comprising a series of shaped, interlaced rigid links 530 extending from mating ends of flexible belt segments 501, 502. As shown in FIGS. 38—43, flexible belt segment 501 comprises a flexible body with drive teeth 506, which can have any suitable configuration. In the embodiment of FIGS. 36 — 43, the rigid links 530 have different widths, with corresponding hollows 531 of different widths to accommodate the different width links. For example, as shown in FIGS. 40 and 41, an edge rigid link 5301 can be wider than adjacent and successive interior links 5302, 5303, 5304, 5305. In addition, while all the rigid links include two longitudinally-spaced apart, laterally-extending openings 540, 541 that are parallel to each other, selected links 5304, 5304, 5305 include windows to the openings 540, 541 from the top or bottom, while other links 5301, 5302 enclose the openings from the top and bottom to enhance the strength of the selected links. The rigid links 530 comprise bodies with angled sidewalls to taper from base to tip.

[0111] As shown in FIGS. 42 and 43, the illustrative series of rigid links 530 for the fastening system 530 includes wider, solid links 5311, 5312, 5313, 5314 in a middle portion, with centermost links 5312, 5313 being wider than adjacent links 5314, 5311. Links 5315, 5316 can include windows to the passageways 540, 541.

[0112] FIG. 44 shows another embodiment of a fastening system 630 for a conveyor belt including flexible belt segments 601, 602 with shaped, rigid, interlocking links 630 extending from mating ends having different widths and selectively including windows to locking passageways. The fastening system 610 is formed on a conveyor belt including two sets of drive teeth 606.

[0113] FIGS. 45 and 46 show another embodiment of a fastening system 710 for a conveyor belt including flexible belt segments 701, 702 with shaped, rigid, interlocking links 730 extending from mating ends. The illustrative belt segments 701, 702 are identical but installed with one belt segment 702 upside down from the other belt segment 701. Each illustrative shaped, rigid link 730 includes an inner laterally-extending opening 740 and an outer laterally-extending opening 741. The link comprises a body extending from a base to a tip. The tip 733 of each link 730 includes bulges 734 around the laterally-extending outer opening 741. The bulges 734 fit into recesses 738 in the sidewalls of opposing links around the inner laterally-extending opening 740. As shown, the recesses 738 include angled walls that angle towards the inner end of the link 730. As shown in FIG. 46, the rigid links 730 can be interlaced and snap-fit together by bringing the first belt segment 702 over the second belt segment 701 so that the openings 740, 741 align along the lines 780, 781 defining the axis of the angled recesses 738. Then, the segments are moved along the lines 780, 781 so that the bulges 734 snap into the recesses 738, automatically aligning the openings 740 and 741 to form passageways for receiving locking prongs. The illustrative fastening system 710 does not include windows to the openings 740, 740, but one or more windows can be provided along the width of the fastening system.

[0114] In another embodiment, shown in FIGS. 47—51, a fastening system 810 for a conveyor belt includes a plurality of interlocking, shaped links 830 with inner and outer locking openings 840, 841 extending laterally through a body that aligns to form locking passageways for receiving prongs of a locking device. The outer openings 841 form truncated bulges 834 at the sides of the link. The bulges 834 are thinner towards the tip 833 of link 830. The bulges 834 interface with shaped, angled recesses 838 surrounding the inner openings 840 to latch interlinked links together 830 and automatically align the locking openings 840, 841 to form locking passageways for receiving the locking prongs.

[0115] As shown in FIG. 49, the base 870 of each connector has a width Wb that is between about 1.5 to about 2.5 times the width Wt of the tip 833 to form tapered connectors, so that the inner locking opening 840 is between about 1.5 to about 2.5 times as long as the outer locking opening 841 and the sidewalls 872, 873 extend at an angle of between about 20° and about 25° and preferably about 22.5° relative to the longitudinal direction.

[0116] The connectors 830 can be individually formed and connected through any suitable process, such as splicing and welding, to an end of a belt segment. A platen or other suitable aligning device can assist in connecting the connectors to the belt segment. Alternatively, groups of connectors can be formed together and connected to a belt segment. In another embodiment, the connectors can be integrally formed with a belt segment.

[0117] Referring to FIGS. 52 and 53, an edge link 860 for a conveyor belt fastening system, such as the fastening system 810 of FIGS. 47—51, can include a solid edge portion 861 aligned with locking passageways 840, 841. The inner side edge 865 of the end link can be shaped to interface a shaped link 830, and include a truncated bulge 874 around the outer locking opening 841 and a shaped, angled recess 878 around the inner locking opening 840. The edge link 860 forms a window 866 between the solid edge 861 and the inner edge for inserting a two-pronged locking device. A longitudinal channel 867 in the bottom wall of the window seats the base of the two-pronged locking device and lateral channels 868 seat the portion of the prongs adjacent the base. A front wall 870 of the edge link 860 connects the solid edge portion 861 to an inner portion in which the locking passageways 840, 841 are formed and bounds the window 866.

[0118] In another embodiment, shown in FIGS. 54—56, an edge portion of a series of linking elements in a conveyor belt fastening system can include two separate links, 961, 962. An outer edge link 961 includes a slotted opening 963 for seating the base of a locking device 950 and a solid edge 964 for preventing migration of the locking device. An inner edge link 962 is separated from the outer edge link 961 by a gap 968 and includes locking passageways 940, 942 for receiving prongs of the locking device 950.

[0119] Referring to FIGS. 57—69, in another embodiment, a fastening system 1110 for a conveyor belt can include shaped, stepped connectors 1130 including inner and outer lateral openings forming locking passageways. Each belt segment 1101, 1102 includes a series of shaped, stepped connectors 1130 that interlace to join the ends of the belt segments. A dualpronged locking mechanism passes through the locking passageways to secure the belt segments together. In the embodiment of FIGS. 57—69, the connectors 1130 are formed of the same material as the belt segments 1101, 1102, but can alternatively be formed of a different material.

[0120] As shown in FIGS. 59—63, each shaped, stepped connector 1130 comprises a body with a relatively wide base 1131 and a narrow tip 1132. An inner lateral opening 1140 extends through the base 1131 and an outer lateral opening 1141 extends through the tip 1132. The tip has a width X, and the base has a width that is between about 1.5 and about 3 times X, as shown in FIG. 60, making the inner lateral opening 1140 longer than the outer lateral opening 1141.

[0121] As shown in FIG. 61, the shaped, stepped connectors have sidewalls 1133, 1134, 1135, 1136 that extend at angles 1173, 1174, 1175, 1176 relative to the longitudinal direction of travel L of the conveyor belt. In this manner, the base 1131 widens before curving to laterally extending walls 1161, 1162, shown in FIGS. 61 and 62, that extend to the tip 1132. The tip 1132 also widens before curving to a laterally extending end wall 1153. In one embodiment, the sidewalls extend at an angle of between about 20° and about 25° relative to the longitudinal direction, and preferably about 22.5° relative to the longitudinal direction.

[0122] While the sidewalls of the stepped, shaped connectors are formed by curves configured to abut a corresponding curve in a mating connector, the stepped, shaped connectors may have other suitable shapes. The shaped sidewalls form a positive overlap when the connectors interlace.

[0123] As shown in FIG. 64, the illustrative locking passageways 1140, 1141, which receive the prongs 1151, 1152 of a locking device, are vertically centered in the connector 1130, which extends below the bottom surface 1117 of the belt segments. The illustrative connector is flush with the top surface 1116 of the belt segments. As shown, the centers of the locking passageways 1140, 1141 align with the bottom surfaces 1117 of the belt segments.

[0124] Referring to FIGS. 65—69, one or both side edges of the fastening system 1110 can include a seat 1160 for a dual-pronged locking device 1150 extending through interlaced connectors 1130. The illustrative seat 1160 is inset from the side edges of the belt segments 1101, 1102. The seat 1160 comprises a recess aligned with the laterally locking passageways 1140, 1141 and including a flexible finger 1181 for engaging the base of the locking device 1150 to secure the locking device in the fastening system 1110.

[0125] In one embodiment, a dual-pronged locking device suitable for use in a conveyor belt fastening system comprising interlacing connectors extending from the ends of mating belt segments can be nitinol or another shape memory alloy that is flexible at a certain temperature range and rigid at another temperature range. A needle or other rigid device can be used to help thread the prongs through the locking passageways.

[0126] The scope of the claims is not meant to be limited to the details of the described exemplary embodiments.

Claims

1. What is claimed is:

1. A fastening system for fastening a first end of a flexible conveyor belt segment to a second end of a flexible conveyor belt segment, comprising: a first shaped connector extending from the first end having sidewalls that are angled relative to a direction of belt travel and including a first inner lateral opening and a first outer lateral opening; a second shaped connector extending from the first end and separated from the first shaped connector by a first hollow, the second shaped connector having sidewalls that are angled relative to a direction of belt travel and including a second inner lateral opening aligned with the first inner lateral opening and a second outer lateral opening aligned with the first outer lateral opening; a third shaped connector extending from the second end and configured to be received by the first hollow, the third shaped connector having sidewalls that are angled relative to a direction of belt travel and including a third inner lateral opening that aligns with the first and second outer lateral openings and a third outer lateral opening that aligns with the first and second inner lateral openings; and a locking device with a first prong inserted through the first inner lateral passageway, second inner lateral opening and third outer lateral opening and a second prong inserted through the first outer lateral opening, second outer lateral opening and third inner lateral opening.

2. The fastening system of claim 1, wherein the locking device includes a base integral with the first and second prongs.

3. The fastening system of claim 1, wherein the locking device comprises a first j- shaped hook and a second j-shaped hook opposing the first j-shaped hook.

4. The fastening system of claim 1, further comprising a plurality of windows from a top surface to at least some of the openings.

5. The fastening system of claim 3, further comprising a plurality of windows from a bottom surface to at least some of the openings.

6. The fastening system of claim 5, wherein each shaped connector includes a tip having bulges configured to be received in divots in a mating belt segment.

7. The fastening system of claim 6, wherein the bulges surround the ends of a corresponding outer lateral opening.

8. The fastening system of claim 6, where the divots are formed by shaped, angled recess around the inner lateral openings.

9. The fastening system of claim 1, further comprising a latch for latching the locking device to the fastening system.

10. The fastening system of claim 1, wherein each lateral opening comprises an upwards-facing saddle open to a top surface of the shaped connector and a downwards- facing saddle open to a bottom surface of the shaped connector.

11. The fastening system of claim 1, wherein the sidewalls extend at an angle of between about 5° and about 25° relative to the direction of belt travel.

12. The fastening system of claim 1, wherein each shaped connector tapers from a base at the end of the belt segment to a tip, and the base is between about 1.5 times to about 2.5 times wider than the tip.

13. The fastening system of claim 1, wherein the sidewalls of the connectors are formed by curves, each curve configured to abut a corresponding curve in a mating connector to form a positive overlap when the connectors interlace.

14. The fastening system of claim 1, wherein the flexible belt segments are formed of a first material with a modulus of elasticity that ranges between about 0.02 GPa to about 0.3GPa and the connectors are rigid and formed of a second material that has a modulus of elasticity that is between about 2 and about 50 times that of the first material.

15. The fastening system of claim 1, further comprising: a first latching connector extending at a first side edge from the first end of the flexible belt segment, the first latching connector including a latching seat on a bottom side for seating a base of a locking device.

16. The fastening system of claim 15, wherein the first latching connector is wider and shorter than the first and second shaped connectors.

17. The fastening system of claim 16, wherein the first latching connector includes an inner passageway that is open to a side edge, intersects the latching seat and aligns with the inner lateral openings of the first and second shaped connectors.

18. The fastening system of claim 15, wherein the latching seat includes a front opening in a front edge and a lateral protrusion for cradling a prong of the locking device.

19. The fastening system of claim 15, further comprising: a second latching connector at a second side edge of the first end, including a latching seat, the second latching connector including an outer portion that is shorter in length than the first and second shaped connectors and equal in length to the first latching connector and an inner portion of that protrudes farther than the outer portion and includes both an outer passageway and an inner passageway.

20. In a fastening system for a conveyor belt, a connector extending from an end of a belt segment comprising: a body tapering in width from a base to a tip and including sidewalls angled relative to a direction of conveyor belt travel; a first laterally-extending opening extending through the body at the base; and a second laterally-extending opening extending through the body at the tip.

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