Cogged V-Belt Manufacturing After Vulcanization to Prevent Layer Cracks
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Solution Overview
Problem
The existing method for manufacturing cogged V-belts results in non-uniform flow of unvulcanized rubber sheets, leading to recess formation and potential cracks or peeling at the interface between rubber layers, which compromises the durability and integrity of the belt.
Innovation Solution
A method involving the formation of an unvulcanized sleeve by laminating rubber sheets with short fibers oriented in the belt width direction, followed by vulcanization and subsequent cog formation, rather than pressurizing the sleeve to form cogs, ensuring uniformity and orientation of fibers and layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the unvulcanized sleeve is pressurized to form cogs by flowing the unvulcanized rubber sheet, then the cogs are formed on the belt inner peripheral side, but the unvulcanized rubber sheet flows non-uniformly causing recess formation and potential cracks or peeling at the interface between rubber layers
Solution Approach 1:
The patent applies preliminary action by pre-forming the unvulcanized sleeve with uniformly controlled rubber layers before the cog formation process. The sleeve is prepared with precise layer thickness and composition, and then vulcanized to establish a stable base structure. This preliminary preparation ensures that when cogs are subsequently formed by pressing, the rubber layers have already been positioned correctly, preventing non-uniform flow and recess formation during the pressing operation.
Solution Approach 2:
The patent utilizes parameter changes by controlling the viscosity and flow characteristics of the unvulcanized rubber sheet through temperature and composition adjustments. By optimizing the rubber compound formulation and processing temperature, the rubber exhibits controlled flow behavior during pressing, ensuring uniform distribution into the mold cavities without creating recesses or voids at the layer interfaces.
2Shape
If the unvulcanized rubber sheet for compression rubber layer flows into the concave portion of the drum, then the cog shape is formed, but the rubber sheet may draw another unvulcanized rubber sheet and become non-uniform
Solution Approach 1:
The patent applies preliminary action by pre-forming the unvulcanized sleeve with uniformly controlled rubber layers before the cog formation process. The sleeve is prepared with precise layer thickness and composition, and then vulcanized to establish a stable base structure. This preliminary preparation ensures that when cogs are subsequently formed by pressing, the rubber layers have already been positioned correctly, preventing non-uniform flow and recess formation during the pressing operation.
Solution Approach 2:
The patent applies local quality by giving different properties to different parts of the rubber compound. The compression rubber layer is formulated with specific viscosity and flow characteristics that differ from other layers, allowing it to flow uniformly into the cog cavities without dragging adjacent layers. This localized property adjustment ensures that each layer maintains its integrity while forming the desired cog shape.
3Shape
If the unvulcanized rubber sheet for compression rubber layer shows different flowing manners in concave and convex portions, then the cog structure is formed, but the thickness of the cog portion becomes non-uniform
Solution Approach 1:
The patent utilizes parameter changes by controlling the viscosity and flow characteristics of the unvulcanized rubber sheet through temperature and composition adjustments. By optimizing the rubber compound formulation and processing temperature, the rubber exhibits controlled flow behavior during pressing, ensuring uniform distribution into the mold cavities without creating recesses or voids at the layer interfaces.
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
This approach enhances the lateral pressure resistance and durability of the cogged V-belt, reducing the occurrence of cracks and peeling, and improves its performance in applications like continuously variable transmission systems.
Implementation Method 1
a vulcanized sleeve formation step of vulcanizing the unvulcanized sleeve after the unvulcanized sleeve formation step, thereby forming a vulcanized sleeve
Data Source
AI summary
A method for manufacturing a cogged V-belt having a plurality of cogs, includes: an unvulcanized sleeve formation step of forming an unvulcanized sleeve by laminating a plurality of unvulcanized rubber sheets that contain at least an unvulcanized rubber sheet for a compression rubber layer and an unvulcanized rubber sheet for a tension rubber layer; a vulcanized sleeve formation step of forming a vulcanized sleeve by vulcanizing the unvulcanized sleeve; and a cog formation step of forming the plurality of cogs on the compression rubber layer after the vulcanized sleeve forming step.