Conveyor Belt Module Grid Geometry for Rubber Retention
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Solution Overview
Problem
Existing methods for attaching high friction resilient materials, such as rubber, to conveyor belt modules, particularly those made from polyacetal resin, fail to provide a secure and long-lasting attachment, leading to potential loosening and detachment during use.
Innovation Solution
A molding technique that creates a unique grid geometry on the module surface with cavities and ribs, allowing the rubber to flow into and surround the ribs, providing a positive mechanical retention that prevents the rubber from being easily removed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical retention methods such as tongue and groove arrangements and fasteners are used to attach the high friction surface to the module, then the attachment is improved, but the device complexity increases and the manufacturing process becomes more complicated
Solution Approach 1:
The patent merges the retention structure directly into the module body through integral molding. The ribs and cavities are formed as part of the module itself rather than being separate components, eliminating the need for additional fasteners or complex retention mechanisms. This integration provides secure attachment while simplifying the overall device structure and manufacturing process.
Solution Approach 2:
The patent employs co-molding techniques to create a composite structure where the high friction resilient material is bonded to the rigid plastic module body. The integral molding process creates a unified composite component where the retention features are built into the module body, combining the benefits of both materials while eliminating complex assembly requirements.
2Ease of manufacture
If the high friction surface is thermally bonded to the module surface without mechanical retention, then the manufacturing process is simplified, but the attachment reliability is insufficient and the material can loosen or fall off during use
Solution Approach 1:
The patent combines thermal bonding with mechanical retention by integral molding. The high friction material is thermally bonded to the module body while simultaneously forming mechanical retention features (ribs and cavities) as part of the same molding process. This dual approach provides both simplified manufacturing and secure attachment, preventing the material from loosening or falling off during use.
3Ease of manufacture
If co-molded rubber top modules with rubber thermally bonded to the flat module surface are used, then the manufacturing process is simplified, but the adhesion is insufficient particularly for polyacetal resin material
Solution Approach 1:
The patent applies local quality by creating specific retention features (ribs and cavities) at the interface between the high friction material and the module body. These localized structural modifications provide enhanced mechanical interlocking and adhesion, particularly for polyacetal resin material, while maintaining the overall simplicity of the co-molding process. The retention features are strategically positioned to maximize bonding strength where needed.
Solution Approach 2:
The patent uses co-molding to create a composite structure where the high friction resilient material is bonded to the rigid plastic module body with integral retention features. This composite approach combines the benefits of both materials and provides sufficient adhesion strength for polyacetal resin while maintaining manufacturing simplicity through the co-molding process.
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 ensures a permanent and secure attachment of the rubber surface to the conveyor belt modules, enhancing friction and preventing loosening, even under repeated use and stress.
Implementation Method 1
A molding technique that creates a unique grid geometry on the module surface with cavities and ribs, allowing the rubber to flow into and surround the ribs, providing a positive mechanical retention that prevents the rubber from being easily removed.
Data Source
AI summary
A belt module having a grid geometry including cavities and ribs associated with an outer surface for attaching a high friction material.