Bonded Belt Fabric With Controlled Width and Reduced Waste
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Solution Overview
Problem
Existing methods for manufacturing high-performance belts result in significant waste and variability in reliability and performance due to limitations in fabric production and processing.
Innovation Solution
A base fabric with modulable warp yarns and rigid weft yarns is produced using a herringbone weave, which is then subjected to a bonding treatment to create a bonded fabric. This fabric is designed to have specific elongation characteristics and is optimized for use in belt manufacturing, reducing waste and improving consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a loom is used to produce fabric with width twice that desired by the customer, then the fabric can be subsequently elastically shrunk in tumblers, but this results in wavy side edges requiring trimming that causes waste and residual tension state variability
Solution Approach 1:
The patent applies preliminary action by pre-calculating and setting the exact width of the base fabric to match the final desired fabric width after bonding treatment, eliminating the need for subsequent trimming operations. The width is determined in advance based on the mold dimensions and bonding shrinkage characteristics, so the fabric is woven to the precise width needed from the start.
Solution Approach 2:
The patent changes the width parameter of the base fabric to be exactly equal to the final desired width rather than producing excess width. This parameter change eliminates material waste while the bonding process provides controlled dimensional stabilization without requiring post-production trimming.
2Loss of substance
If the base fabric width is reduced to match the final desired width, then waste is reduced, but the variability in dimensional control increases due to the bonding treatment process
Solution Approach 1:
The patent changes the width parameter of the base fabric to be exactly equal to the final desired width, eliminating waste while using the bonding treatment to provide dimensional stabilization. The bonding process parameters are controlled to ensure consistent dimensional outcomes.
Solution Approach 2:
The patent uses composite materials by bonding the base fabric with a polymeric matrix that provides dimensional stabilization. This composite structure maintains precise dimensions through the bonding treatment while eliminating the need for excess width and subsequent trimming.
3Productivity
If the bonded fabric is divided into n portions and rotated by 90° for assembly, then the fabric can be optimized for belt manufacturing, but this process procures additional waste and increases process complexity
Solution Approach 1:
The patent applies preliminary action by pre-orienting the base fabric with the correct grain direction and dimensions before bonding, so that the final fabric requires no rotation or division into portions. The width is set in advance to match the mold dimensions, eliminating subsequent repositioning operations and associated waste.
4Ease of manufacture
If the warp yarns are made elastic and weft yarns rigid, then the fabric can be shrunk elastically in tumblers, but this creates uncontrollable residual tension state in the weft direction
Solution Approach 1:
The patent inverts the traditional yarn assignment by making warp yarns rigid and weft yarns elastic. This inversion allows the elastic direction (weft) to accommodate dimensional changes during bonding without creating uncontrollable tension, while the rigid warp provides structural stability. The bonding treatment is applied with the fabric oriented to utilize this inverted yarn configuration.
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 process significantly reduces waste and enhances the reliability and performance consistency of the belts by allowing for precise control over fabric dimensions and properties, leading to more efficient and repeatable manufacturing outcomes.
Implementation Method 1
the warp yarns (2) are elastic, in that they undergo shrinkage, with elastic recovery, in the longitudinal direction
Implementation Method 2
undergo a shrinkage process, during which the longitudinal elongation of the fabric, due to the pretensioning, is recovered
Implementation Method 3
The molded semifinished product is then subjected to vulcanization
Data Source
AI summary
A process for manufacturing a bonded fabric for high performance industrial belts is provided. The process includes providing a base fabric made up of warp yarns provided with a predetermined elasticity and weft yarns provided with a lower elasticity than the warp yarns, and subjecting the base fabric to a bonding treatment.