Elevator Traction Belt Individual Cord Coating Alignment

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Solution Overview

Problem

Existing methods for manufacturing elevator traction belts, such as those using a mold wheel process, face challenges in controlling cord position and securing elastomer jackets, leading to grooves on the exterior surface and limitations in jacket thickness and uniform coating.

Innovation Solution

Applying individual coatings to each tension member and joining them to form a single jacket, allowing for precise alignment and varied geometry, with optional additional materials for modified surface characteristics and features like fiber optics or conductive members.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a mold wheel process is used to support cords during manufacturing, then the belt can be formed with a jacket material, but grooves are created on the exterior surface of the jacket

Engineering Contradiction:

Improvebelt manufacturing processVSAvoidexterior surface smoothness

Core Design Contradiction:

Ease of manufactureVSShape

Solution Approach 1:

The patent applies segmentation by individually coating each cord separately rather than coating all cords simultaneously on a mold wheel. This individual coating approach eliminates the grooves that form when cords are supported on a rotating mold wheel, as each cord is coated independently and then joined with adjacent cords to form the complete belt jacket.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If elastomer flow is required to uniformly coat each cord, then good control on outer dimensions is achieved, but the jacket layer thickness cannot be made thinner than a certain limit

Engineering Contradiction:

Improveouter dimension controlVSAvoidjacket layer thickness

Core Design Contradiction:

Manufacturing precisionVSLength of moving object

Solution Approach 1:

The patent applies partial action by coating each cord individually with a thin layer of jacket material, then joining the coated cords together. This approach allows for precise control of the outer dimensions while achieving thinner overall jacket thickness compared to the mold wheel process, which requires a thicker elastomer layer to ensure complete and uniform coating of all cords simultaneously.

Inventive Principle:

Principle #16Partial or excessive action

3Productivity

If the orifice is made wide enough to allow linear flow at high speeds, then practical manufacturing speeds are achieved, but the jacket thickness is constrained

Engineering Contradiction:

Improvemanufacturing speedVSAvoidjacket layer thickness

Core Design Contradiction:

ProductivityVSLength of moving object

Solution Approach 1:

The patent segments the coating process into individual cord coatings rather than a single continuous coating operation. This segmentation allows for faster manufacturing speeds because each cord can be coated independently and efficiently, then joined with adjacent cords. The linear extrusion process with individual cord coating achieves practical speeds without the thickness constraints of the mold wheel process.

Inventive Principle:

Principle #1Segmentation

4Ease of manufacture

If cords are supported on a mold wheel during manufacturing, then the belt structure can be formed, but the position of cords cannot be controlled and maintained precisely

Engineering Contradiction:

Improvebelt structure formationVSAvoidcord position control

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent segments the cord support and coating process, allowing each cord to be positioned and coated independently before being joined with adjacent cords. This individual handling approach enables precise control and maintenance of cord positions throughout the manufacturing process, eliminating the position control problems that occur when cords are supported on a rotating mold wheel.

Inventive Principle:

Principle #1Segmentation

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

This method enables better control over cord position and geometry, allowing for thinner or thicker coatings, diverse surface characteristics, and faster, cost-effective manufacturing with increased material versatility and consistency.

Implementation Method 1

the jacket material must flow during the manufacturing process to provide good control on the outer dimensions of the jacket

Methodology Applied

Scientific EffectFlow:

Implementation Method 2

A portion of the individual coatings are joined together to secure the tension members into a desired alignment and to form a single jacket

Methodology Applied

Scientific EffectBonding:

Data Source

PatentUS8677726B2Method of making an elevator belt

Publication Date: 2014.03.25 OTIS ELEVATOR CO

AI summary

An exemplary method of making a load bearing elevator traction belt includes applying individual coatings of a jacket material to each of a plurality of tension members such that each tension member is individually coated separately from the other tension members. A portion of the individual coatings are joined together to secure the tension members into a desired alignment and to form a single jacket that establishes a geometry of the belt.