Drive Belt Manufacturing Using Pre-Stretched Textile Layer
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Solution Overview
Problem
Existing methods for manufacturing drive belts are complex and require multiple steps, with limited efficiency in distributing elastomer base material evenly across the geometry, leading to suboptimal load absorption and strength distribution.
Innovation Solution
A method involving a casting tool with a mould core and outer mould, where a textile layer is fixed using a tension member on a geometry with projections and gaps, allowing the elastomer base material to fill the cavity and penetrate through the tension member layer, ensuring uniform strength and load absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the textile layer is placed on the geometry and underpressure is generated to support placement, then the textile layer adheres to the geometry, but the manufacturing process becomes complex with multiple steps
Solution Approach 1:
The textile layer is pre-stretched in the region of the gaps before placing it on the geometry. This preliminary action ensures that the textile layer automatically adheres to the geometry when placed, eliminating the need for subsequent underpressure generation and multiple complex steps while maintaining precise placement.
Solution Approach 2:
The patent extracts and eliminates the underpressure generation step from the manufacturing process. By pre-stretching the textile layer, the adhesive function previously achieved through underpressure is replaced, simplifying the overall manufacturing process while maintaining placement precision.
2Strength
If elastomer base material is introduced into the cavity to fill gaps and form the drive belt, then load absorption is improved, but the manufacturing time increases due to multiple work steps
Solution Approach 1:
The textile layer is pre-stretched in the gap regions before cavity formation. This preliminary action creates optimal pathways for elastomer base material distribution, ensuring uniform strength and load absorption while reducing the time required for material introduction and cavity filling.
Solution Approach 2:
The patent changes the physical state and distribution parameters of the elastomer base material by introducing it in a controlled manner after pre-stretching the textile layer. This ensures optimal penetration and distribution of the elastomer throughout the cavity, achieving uniform strength distribution while minimizing manufacturing time.
3Manufacturing precision
If the textile layer is stretched in the region of the gaps, then uniform strength distribution is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the textile layer placement step with the gap region pre-stretching step into a single integrated operation. By combining these actions, uniform strength distribution is achieved without adding separate complex process steps, as the pre-stretching is performed concurrently with placement rather than as a separate subsequent operation.
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 simplifies the manufacturing process, enhances load-bearing capacity, and extends the service life of drive belts by ensuring uniform strength distribution and improved load absorption.
Implementation Method 1
an elastomer base material is introduced into the cavity of the casting tool and held there until it solidifies
Data Source
AI summary
The invention is used to manufacture a drive belt. To this end, mould core (1) and outer mould (20) of a casting tool (G) are provided. In the case of mould core (1) inserted into the outer mould (20), a cavity (22) is formed in the casting tool (G). The mould core (1) or the outer mould (20) are provided with a geometry (2) to be represented on the drive belt. Said geometry has projections (3a, 3b) protruding from a base surface (8) and arranged spaced apart from one another, which have a head surface (7) and lateral surfaces (5, 6) which each delimit a gap (4) of the geometry (2) with in each case a base surface (8) present between two adjacent projections (3a, 3b). A textile layer (12) is laid on the geometry (2), which is supported on the head surfaces (7) and in each case extends with a section (13) over the gaps (4). A tension member (13) is laid on the textile layer (12) such that the textile layer (12) is fixed between the tension member (14) and the respective head surface (7). At the same time, an intermediate space (17) between the section (13) of the textile layer (12) extending over the gap (4) and the section (18) of the tension member (14) spanning the gap (4) is delimited in each gap (4). The cavity (22) and the intermediate spaces (17) are filled with a castable elastomer base material (B) after inserting the thus provided mould core (1) into the outer mould (20). As a result, the sections (13) of the textile layer (12) are pressed by the elastomer base material (B) against the lateral surfaces (5, 6) of the projections (3a, 3b) and the assigned base surface (8) of the respective gap (4). The drive belt sleeve obtained can be demoulded after the base material has solidified.