Embedded Electronics in Elastomer Belts Without Vulcanization Damage
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Solution Overview
Problem
Existing methods for producing belt- or band-shaped components with integrated electronics face challenges such as damage from vulcanization processes, inhomogeneous material structure, and exposure to tensile and compressive loads, leading to reduced service life and potential destruction of electronic components.
Innovation Solution
A method involving the insertion of non-vulcanizable planar intermediate plies into the component blank before vulcanization, allowing for the creation of a receiving space for the electronic circuit, which is then introduced and encapsulated, thereby protecting it from environmental influences and loads, using materials like Teflon or silicone paper and ensuring a 'floating' arrangement to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electronics are integrated into the belt component through vulcanization, then the electronic components are protected from environmental influences, but the vulcanization process causes damage to the electronic components and creates an inhomogeneous material structure
Solution Approach 1:
The belt component is divided into distinct regions: vulcanizable elastomer material and non-vulcanizable pockets containing electronics. This segmentation allows different parts to undergo different processes - the elastomer is vulcanized for strength while the electronics remain protected from vulcanization damage within isolated pockets.
Solution Approach 2:
Pockets made of non-vulcanizable material serve as intermediaries between the vulcanization process and the electronic components. These pockets act as protective barriers that prevent direct contact between the electronics and the harsh vulcanization environment while still allowing integration into the overall belt structure.
2Productivity
If the component is subjected to tensile and compressive loads during operation, then the belt performs its driving function, but the electronic components are exposed to damaging mechanical stresses
Solution Approach 1:
The belt structure separates load-bearing functions from electronic functions. The elastomer material and tension members bear tensile and compressive loads, while the electronics are isolated in pockets that prevent stress transfer, allowing each component to operate in its optimal stress environment.
Solution Approach 2:
The non-vulcanizable pockets are designed in advance to absorb and isolate mechanical stresses before they can reach the electronic components. This beforehand cushioning protects the electronics from the full force of operational loads while maintaining the belt's driving capability.
3Reliability
If the belt is replaced after short use periods to prevent damage, then machine downtime is reduced, but maintenance costs and resource waste increase
Solution Approach 1:
The electronic monitoring system is extracted as a separate integrated component within the belt, allowing continuous monitoring of belt condition. This enables predictive maintenance where belts are replaced based on actual condition rather than fixed schedules, reducing unnecessary replacements and resource waste.
Solution Approach 2:
The integrated electronics provide real-time feedback on belt condition through sensors that monitor stress, temperature, and other parameters. This feedback loop enables condition-based maintenance, allowing operators to replace belts only when actually needed, optimizing both reliability and resource utilization.
Data Source
AI summary
The invention relates to a method for producing a belt- or band-shaped component made of elastomer material, which is driven to run around under tensile stress and which has an electronic circuit or electronic device installed in the component, the component having tension members or cords which are arranged in the longitudinal direction, wherein, during the fabrication and before the vulcanization of the component blank, planar intermediate plies or strips made of material which cannot be crosslinked by vulcanization are inserted into the blank structure in subregions of the blank, wherein, after the fabrication, the blank is completely vulcanized to form the component and, where appropriate, cut or trimmed, and wherein the intermediate plies or strips are then removed from the component through correspondingly incorporated or method-intrinsically formed openings, and an electronic circuit or electronic device is introduced into the thus resulting planar empty space or interspace in the component.