Elevator Support Belt Layer Bonding via Protruding Tensile Carriers
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Solution Overview
Problem
Existing methods for producing support belts for elevator installations do not achieve a strong enough connection between the first and second belt layers, leading to potential mechanical failures and reduced efficiency in force transmission.
Innovation Solution
A two-stage production method where cable-like tensile carriers are embedded as fully as possible in the first plasticizable material of the first belt layer, with the protruding sections covered by the same material, and a second belt layer is molded on top, ensuring a larger connecting surface area for a robust bond between the layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tensile carriers are embedded only to half in the first belt layer as in known methods, then the production process is simpler, but the connection strength between belt layers is insufficient
Solution Approach 1:
The first belt layer is produced in advance with tensile carriers protruding from its surface, creating a prepared substrate that receives the second belt layer. This preliminary formation of the first layer with exposed carriers enables subsequent molding of the second layer to envelop the carriers, establishing strong mechanical interlocking between layers before final assembly.
Solution Approach 2:
The second belt layer is molded to envelop and enclose the protruding sections of the tensile carriers, creating a nested structure where the carriers are embedded within the second layer. This nesting arrangement ensures that the carriers are securely anchored in both belt layers, significantly enhancing the connection strength between layers.
2Strength
If the connecting surface area between belt layers is increased, then the mechanical strength improves, but the production time increases
Solution Approach 1:
The production method combines the formation of the first belt layer with the embedding of tensile carriers in a single integrated process. The carriers are positioned and partially embedded during the molding of the first layer, eliminating separate operations for carrier installation and layer bonding, thus reducing production time while maintaining large connecting surface area.
Solution Approach 2:
The tensile carriers are pre-positioned and partially embedded in the first belt layer before the second layer is molded. This preliminary arrangement ensures that when the second layer is formed, the carriers are already in optimal positions for creating extensive connecting surface area, eliminating the need for additional time-consuming alignment and positioning steps.
3Reliability
If tensile carriers are fully embedded in the first belt layer, then the connection between layers is stronger, but the protruding sections require additional material covering
Solution Approach 1:
The first belt layer is produced with non-uniform thickness, featuring localized thickening regions at the embedding locations of the tensile carriers. These localized material accumulations provide sufficient coverage and bonding area for the carrier sections that protrude from the main belt body, ensuring reliable force transmission without requiring excessive material throughout the entire belt structure.
Solution Approach 2:
The molding parameters for the first belt layer are adjusted to create variable material distribution, with increased material density and thickness in specific zones where tensile carriers are embedded. This parameter modification allows the material to adaptively cover the protruding carrier sections, achieving reliable connections while optimizing material consumption through localized rather than uniform material distribution.
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 enhances the connection between the belt layers, improving the mechanical strength and efficiency of force transmission in elevator installations, reducing the risk of mechanical failures and enhancing the overall performance of the support belt.
Implementation Method 1
embedding the at least one cable-like tensile carrier in a first belt layer of a first plasticizable material in such a manner that a part-belt with a first outer surface and a surface forming a connecting plane arises, in which the at least one tensile carrier protrudes partly out of the connecting plane of the part-belt
Implementation Method 2
molding on a second belt layer of a second plasticizable material at the connecting plane of the part-belt and the protruding sections of the at least one tensile carrier
Data Source
AI summary
A process for producing a support belt for an elevator system includes steps of: placing at least one cable-shaped tension support in position; embedding the tension support in a first belt layer made from a first plasticizable material to produce a partial belt having a first outer surface and a surface which forms a connecting plane, wherein parts of the tension support project out of the connecting plane and at least parts of the projecting portion of the tension support are covered by the first plasticizable material; and integrally forming a second belt layer made from a second plasticizable material on the connecting surface of the partial belt and the projecting portions of the tension support so as to produce a support belt having the first outer surface on the side of the first belt layer and a second outer surface on the side of the second belt layer.