Drive Belt Electronics Integration Using Post-Vulcanization Cavities
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Solution Overview
Problem
Existing methods for integrating electronic components into drive belts suffer from damage during vulcanization and are susceptible to stretching and compression, leading to reduced service life and unreliable operation.
Innovation Solution
A method for manufacturing a drive belt with integrated electronics involves inserting non-vulcanizable intermediate layers during assembly, creating a cavity for the electronics, which are then inserted after vulcanization, and securing them with a thermoplastic seal, allowing the electronics to float relative to the main load directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate production processes are used for the belt body and electronic device, then manufacturing flexibility is maintained, but production time and costs increase
Solution Approach 1:
The patent combines the production of the belt body and electronic device into a single integrated process. The electronic device is embedded within the belt body during the molding process, eliminating the need for separate production and assembly steps. This merging of processes reduces overall production time while maintaining manufacturing efficiency.
Solution Approach 2:
The electronic device is pre-positioned and embedded within the belt body structure during the molding process. This preliminary integration ensures that the electronic device is already in its final position and orientation before the belt is completed, eliminating subsequent assembly steps and reducing production time.
2Adaptability or versatility
If complex assembly processes are used to integrate electronic devices into belts, then functional integration is achieved, but manufacturing costs and complexity increase
Solution Approach 1:
The patent merges the manufacturing of the belt body and electronic device into a single integrated molding process. The electronic device is embedded within the belt body during production, eliminating the need for separate assembly operations. This approach reduces manufacturing complexity and costs while achieving complete functional integration.
Solution Approach 2:
The belt product is designed to serve multiple functions simultaneously: mechanical power transmission through the belt body and electronic control/signaling through the embedded device. This multi-functionality is achieved through integrated production, allowing a single product to replace what would traditionally require separate mechanical and electronic components and assembly steps.
3Adaptability or versatility
If electronic devices are embedded in belts, then product functionality is enhanced, but manufacturing precision requirements increase
Solution Approach 1:
The electronic device is pre-positioned within the mold cavity before the belt material is injected. This preliminary positioning ensures precise placement of the electronic device at the exact desired location and orientation. The molding process then encapsulates the device in place, maintaining manufacturing precision without requiring complex post-assembly operations.
Solution Approach 2:
The mold structure serves as an intermediary that precisely positions and secures the electronic device during the molding process. The mold cavity and positioning features act as a mediator between the electronic device and the belt material, ensuring accurate embedding while protecting the sensitive electronic components during manufacturing.
Data Source
Figure 1~2
AI summary
The invention relates to a method for manufacturing a belt- or band-shaped component (1) made of elastomeric material, driven circumferentially under tensile stress, with an electronic circuit or electronic device (7) integrated into the component, wherein the component has longitudinally arranged tensile members or cords (5), wherein during assembly and before vulcanization of the component blank, planar intermediate layers or strips of non-vulcanizable material are inserted into the blank structure in partial areas of the blank, wherein after assembly the blank is vulcanized to form the component and, if necessary, cut or trimmed, and wherein the intermediate layers or strips are then removed from the component through appropriately introduced or process-inherent openings, and an electronic circuit or electronic device (7) is inserted into the resulting planar void or space (9) in the component.