Power Transmission Belt Mold Releasing Layer for Hole Prevention
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Solution Overview
Problem
Power transmission belts with teeth spaced at regular intervals often develop discrete holes during manufacturing, which can lead to crack formation and reduced durability due to the folding of rubber into recesses during the shaping process, and existing methods to eliminate these holes generate significant scrap material.
Innovation Solution
A method involving a rubber layer being pressed against a mold with alternating projections and recesses to form teeth and troughs, followed by local pressure on the opposite side to prevent hole formation, and subsequent joining with other components to form a power transmission belt without generating scrap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a rubber layer is pressed against a mold with alternating projections and recesses to form teeth and troughs, then the belt acquires the desired shape with teeth and troughs, but discrete holes form in the rubber layer at the recess locations due to folding
Solution Approach 1:
A releasing layer is applied to the mold surface before forming the rubber layer. This preliminary action prevents the rubber from adhering to the mold recesses, thereby preventing discrete hole formation while still allowing the teeth and troughs shape to be formed correctly.
Solution Approach 2:
A releasing layer acts as an intermediary between the mold surface and the rubber layer. This intermediary prevents direct contact and adhesion between the rubber and mold recesses, eliminating the folding that causes discrete holes while maintaining the desired belt shape.
2Reliability
If cutting, grinding, or polishing processes are used to eliminate discrete holes, then the reliability of the belt is improved, but significant scrap material is generated
Solution Approach 1:
Instead of removing material to eliminate discrete holes (which creates scrap), the invention uses a releasing layer to prevent hole formation in the first place. The mold recesses, which cause the problem, are converted into a beneficial feature by using them to apply localized pressure that eliminates holes without material removal.
Solution Approach 2:
The harmful adhesion between rubber and mold is extracted by introducing a releasing layer. This allows the rubber to be released from the mold recesses before discrete holes can form, eliminating the need for subsequent scrap-generating removal processes.
3Manufacturing precision
If the rubber layer is pressed deeply into the mold recesses to ensure complete tooth formation, then the shape precision is improved, but discrete holes are more likely to form due to increased folding
Solution Approach 1:
The releasing layer is applied beforehand to prevent rubber adhesion to the mold. This allows the rubber to be pressed deeply into the recesses for precise tooth formation without the rubber sticking and folding, which would create discrete holes.
Solution Approach 2:
The releasing layer provides localized non-adhesion at the mold recess surfaces where discrete holes would form, while allowing complete contact and adhesion in the tooth region. This local differentiation enables deep pressing for precision without the harmful folding effect.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively eliminates discrete holes, reducing the likelihood of cracks and improving belt durability while minimizing waste by integrating the pressure process into the belt formation without additional scrap generation.
Implementation Method 1
The rubber sheet/layer is pressed against the shaping die/mold under controlled temperature and pressure conditions to cause the sheet/layer to conform to the projections/recesses on the shaping die/mold
Implementation Method 2
locally pressing the second side of the first layer at locations coinciding lengthwise with the teeth to thereby eliminate or prevent the formation of discrete holes
Implementation Method 3
Vulcanization is then carried out under controlled pressure and temperature conditions
Data Source
AI summary
A power transmission belt having a body with an inside, an outside, and a length. The body has a tension section and a compression section, and teeth and troughs alternating lengthwise of the body. A layer on the body in which the teeth are formed has a surface facing in one of an inside and outside direction on which alternating protrusions and recesses are formed against which another component on the body is placed and conforms.