Conveyor Belt Curing via Double Belt Press
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Solution Overview
Problem
Conventional conveyor belt manufacturing methods require labor-intensive Banbury mixing and calendaring steps, which are costly and time-consuming, and do not efficiently produce high-temperature-resistant belts with cured rubber components.
Innovation Solution
A continuous process using a double belt press to apply and cure a rubber composition and thermoplastic elastomer composition on a fabric reinforcement, reducing the need for Banbury mixing and calendaring by producing an uncured belt structure that is then heated and pressed to create a cured conveyor belt with high temperature resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional Banbury mixing and calendaring methods are used to manufacture conveyor belts with cured rubber components, then high temperature resistance is achieved, but the manufacturing process becomes labor-intensive and time-consuming
Solution Approach 1:
The invention changes the curing method by using a continuous heating process in a heated press at temperatures of 140°C to 200°C for 10 to 60 minutes, replacing the traditional Banbury mixing and calendaring approach. This parameter change in the curing process achieves high temperature resistance while dramatically improving manufacturing efficiency and reducing labor requirements
Solution Approach 2:
The invention implements a continuous manufacturing process where the uncured belt structure is continuously fed into a heated press for continuous heating and curing. This continuous action eliminates the batch processing nature of conventional methods, thereby improving productivity while maintaining the high temperature resistance properties of the cured rubber
2Reliability
If conventional Banbury mixing and calendaring steps are used, then cured rubber components are produced, but labor and energy requirements increase
Solution Approach 1:
The invention replaces the mechanical Banbury mixing and calendaring system with a thermal curing system. By substituting mechanical mixing and forming with a continuous heating and pressing process, energy requirements are reduced while maintaining consistent rubber formulation and achieving reliable high temperature resistance
3Temperature
If traditional multi-step manufacturing processes are used to create conveyor belts with cured rubber, then high temperature resistance is achieved, but the manufacturing process complexity increases
Solution Approach 1:
The invention merges multiple traditional steps (mixing, calendaring, and curing) into a single integrated continuous heating and pressing operation. By combining these separate processes into one unified step using a heated press, the device complexity is reduced while still achieving the high temperature resistance properties of cured rubber components
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 method simplifies the manufacturing process, reduces labor and energy requirements, and achieves improved rubber formulation consistency while maintaining high temperature resistance, thus lowering production costs and increasing efficiency.
Implementation Method 1
heating the uncured belt structure in the double belt press to a temperature of at least 148.9°C (300°F)
Implementation Method 2
pressing the productive thermoplastic elastomer composition together with the fabric reinforcement at a pressure of at least 82.7 kPa (12 psi)
Data Source
Figure 1
AI summary
Methods of manufacturing a conveyor belt (126) include applying a rubber composition (114) to a first side of fabric reinforcement (112) and scattering productive thermoplastic elastomer pellets (106) onto a second side of the fabric reinforcement to produce an uncured belt structure (120). The uncured belt structure (120) is continuous fed into a double belt press (116) to press the productive thermoplastic elastomer pellets (106) together with the fabric reinforcement (112) to produce an uncured belt (128). Uncured belt (128) is then heated in the double belt press (116) to a temperature of at least 300°F and maintained in the double belt press (116) under a pressure of at least 12 psi and a temperature of at least 300°C for a residence time of at least 20 minutes to produce a cured conveyor belt (130), which is continuously withdrawn from the double belt press (116).