Conveyor Belt Module With Fixed Axles and Interleaved Hinges
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Modular plastic conveyor belts with roller-top designs face challenges in stiffness, manufacturing complexity, and increased material costs due to the need for steel axles and additional support structures, which complicate both manufacturing and operation.
Innovation Solution
A conveyor belt module design featuring interleaved hinge elements and embedded axles, allowing for reduced support surface area and simplified manufacturing through a multi-step injection molding process, where the axle is molded unitarily with the module or embedded within it, using different materials for optimal properties and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steel axles are used in roller-top conveyor belts, then the rollers can be mounted and article support is provided, but the manufacturing complexity increases and material costs rise
Solution Approach 1:
The patent combines the axle and module into a single integrated component. The axle is molded directly into the module body, eliminating the need for separate axle installation and securing steps. This merging of components reduces manufacturing complexity while maintaining the structural integrity needed for reliable article support.
Solution Approach 2:
The module body serves multiple functions: it provides the structural framework, contains the bearing cavities, and integrates the axles as integral components. This multi-functionality eliminates the need for separate axle components and simplifies the overall structure while maintaining reliability for article support.
2Reliability
If steel axles with cavities are used for rollers, then rollers can be mounted, but the plastic modules become less stiff and require more underlying support area
Solution Approach 1:
By merging the axle into the module body as an integral component, the design eliminates the need for separate cavities that would compromise structural stiffness. The axle is formed as part of the molded module, maintaining material continuity and structural integrity throughout the module body.
Solution Approach 2:
The axle is integrated only where needed - in the specific locations where rollers require mounting - rather than creating full cavities throughout the module. This localized integration maintains the stiffness of the surrounding module structure while providing the necessary roller mounting functionality.
3Strength
If more wearstrips are added to support wide roller-top belts, then the belt can support more weight, but friction increases and air flow is obstructed
Solution Approach 1:
The integration of axles into the module body creates a lighter overall structure that requires less underlying support. This reduces the number of wearstrips needed to support the belt, thereby reducing friction and improving air flow while maintaining adequate support capacity through the strengthened module design.
4Ease of manufacture
If axles are encapsulated in molded modules, then manufacturing is simplified, but the axles cannot be easily replaced or adjusted
Solution Approach 1:
The axle is designed as an integral part of the module that can be molded together with the module body. This integration simplifies manufacturing by reducing the number of separate components and assembly steps. The axle remains accessible through the module design, allowing for replacement if needed while maintaining the manufacturing simplicity benefits of integration.
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 design enhances the stiffness of the conveyor belt, reduces manufacturing complexity, and lowers material costs while maintaining effective article support and operational efficiency.
Implementation Method 1
molding the intermediate portion around an end of the axle, thereby embedding the axle end in the intermediate portion
Data Source
Figure 1~2
Figure 3~17C
Figure 5~19B
AI summary
A modular roller-top conveyor belt and rollers for the belt. The roller-top belt has axles that are fixed relative to the module body. Each of the pieces of the multi-piece rollers can be installed radially onto an axle and joined together in a puzzle pattern to form a complete roller that can rotate on the axle. Parallel ridges extending across the width of the modules add stiffness to the belt.