Modular Conveyor Mat Conductive Frame for Electrostatic Dissipation
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Solution Overview
Problem
Modular conveyor mats made of plastic materials are prone to electrostatic charging, leading to hazardous electric shocks when accessible to persons, and existing solutions to mitigate this either increase costs or compromise the material's strength, limiting their use in longer conveyors and higher-speed applications.
Innovation Solution
Incorporating electrically conductive reinforcing strips and hinge pins that form a grid of discharge contacts within the plastic modules, allowing for controlled electrostatic dissipation through conductive footwear, while maintaining the material's strength and cost-effectiveness, and optionally enhancing the conveyor's stiffness and wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If plastic material with electrostatic counteracting additives (e.g., graphite) is used, then electrostatic charging is reduced, but material tensile strength decreases and costs increase
Solution Approach 1:
The conveyor mat is divided into modular sections with discrete coupling elements. The electrostatic discharge function is segmented into specific discharge contacts within the coupling elements, separating the structural plastic material from the electrostatic management function.
Solution Approach 2:
Metal coupling elements and discharge contacts serve as intermediary components between the plastic mat modules and the electrostatic charge. These intermediaries provide the conductive path for charge dissipation without requiring the plastic material itself to have electrostatic properties.
2Ease of manufacture
If conventional plastic modules are used, then cost-effectiveness and ease of manufacture are maintained, but electrostatic discharge hazards occur in person-accessible conveyors
Solution Approach 1:
The coupling elements serve multiple functions simultaneously: mechanical connection between modules, structural reinforcement, and electrostatic charge dissipation. This merging of functions adds safety without requiring separate electrostatic components.
Solution Approach 2:
The metal coupling elements perform multiple roles: they provide mechanical coupling strength, serve as structural reinforcement, conduct electrostatic charges to ground, and enable modular assembly. This multi-functionality addresses several requirements with a single component type.
3Adaptability or versatility
If modular conveyor mats are used for long-distance conveyors, then flexibility and ease of assembly are maintained, but electrostatic charge build-up increases with conveyor length
Solution Approach 1:
The discharge contacts create a continuous electrostatic discharge path along the entire length of the modular conveyor mat. Each coupling element provides a discharge contact that connects to adjacent modules, ensuring continuous charge dissipation throughout the system.
4Reliability
If flame retardant requirements are imposed, then safety standards are met, but suitable plastic materials with adequate strength become unavailable
Solution Approach 1:
The conveyor mat system uses a composite structure combining plastic material for the mat body with metal coupling elements and reinforcing strips. This composite approach allows the plastic to be optimized for flame retardancy while the metal components provide the necessary mechanical strength.
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 solution effectively prevents powerful electric shocks by dissipating electrostatic charges, allowing for the use of modular conveyor mats in longer and faster systems without increasing costs or compromising strength, while maintaining the advantages of modular design and ease of assembly.
Implementation Method 1
the reinforcing strips and the hinge pins are manufactured from electrically conductive material and together form an electrically conductive frame for carrying off electrostatic charge
Implementation Method 2
through contact friction, the plastic upper surface of the modules can very easily obtain a locally high potential
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
Modular conveyor mat (1), comprising a number of rows (2) of modules (3), successive in the conveying direction (P) of the conveyor mat, which modules are provided with a body part (4) from plastic extending transversely to the conveying direction, which is provided with an upper surface (5), and which is provided, viewed in conveying direction, at the front (8) and rear (9) with a series of coupling elements (11) spaced apart with mutual interspaces (10). Coupling elements and interspaces of modules successive in conveying direction interdigitate, and are hingedly coupled with the aid of pins (12). The conveyor mat is provided with reinforcing strips (14) included in the body parts of the modules, spaced apart at a mutual intermediate distance transversely to the conveying direction, which extend in conveying direction between successive hinge pins, and which are provided adjacent their ends (15) with recesses (16) in which the hinge pins successive in conveying direction are received. The reinforcing strips extend at least locally through the upper surface of the modules and form a grid (20) of discharge contacts (18). The reinforcing strips and the hinge pins are manufactured from electrically conductive material, and form an electrically frame for carrying off electrostatic charge.