Filled Carcass Strands for Stronger Belt Clamp Connections
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Solution Overview
Problem
Existing methods for producing tension members, such as steel cables, often result in air pockets between strands, which weaken the clamping connection and limit the transmission of tensile forces, especially in applications like conveyor belts where elastomeric materials can yield and reduce clamping force.
Innovation Solution
Filling the interstices between tension member strands with an elastic and incompressible filling material, such as vulcanized rubber or polyurethane, to enhance the clamping effect and prevent air pockets, thereby increasing the strength and reliability of the press or clamp connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If crimping under very high forces is used to improve clamping connection, then the maximum transmissible force increases, but air pockets remain between strands reducing connection effectiveness
Solution Approach 1:
The patent removes air pockets from the spaces between tension member strands by replacing them with filling material during the manufacturing process. This extraction of the harmful air voids ensures complete material contact between strands, enabling reliable force transmission throughout the clamping connection without the weaknesses caused by air pockets.
Solution Approach 2:
The patent introduces a filling material as an intermediary substance that occupies the spaces between tension member strands. This filling material acts as a mediator that transmits clamping forces uniformly across all strands, replacing the non-transmissive air pockets and ensuring consistent force distribution throughout the connection.
2Strength
If elastomeric material surrounds tension members from the outside, then the tension members are protected and integrated, but the elastic material can deflect clamping force laterally reducing maximum clamping force
Solution Approach 1:
The patent applies filling material specifically in the local regions where tension member strands are positioned, rather than using elastomeric material throughout. This localized filling ensures that clamping forces are transmitted directly to the strands without lateral deflection, while maintaining protection only where the strands are embedded in the elastomeric material.
Solution Approach 2:
The patent creates a composite structure by combining filling material (for force transmission) with elastomeric material (for protection and integration). The filling material provides rigid force transmission paths between strands, while the elastomeric material provides external protection and flexibility, creating a composite system that benefits from both material properties.
3Reliability
If spaces between strands are filled with filling material, then force transmission between strands is improved, but the complexity of the manufacturing process increases
Solution Approach 1:
The patent performs the filling operation during the initial manufacturing process, before the tension member is put into service. By pre-filling the spaces between strands with filling material during manufacturing, the complex operation is performed once during production rather than requiring complex assembly or treatment during installation or maintenance.
Solution Approach 2:
The patent combines the filling operation with the existing manufacturing process for creating tension members with clamping connections. By integrating the filling step into the standard manufacturing sequence, the process complexity is minimized and the benefit of improved force transmission is achieved without requiring separate complex processing steps.
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 approach strengthens the clamping connection by allowing for more effective force transmission between strands, reduces the risk of damage during pressing, and maintains the structural integrity and flexibility of the tension member, while also preventing corrosion and buckling.
Implementation Method 1
filling the spaces between the strands with a filling material, in particular with an elastic but incompressible filling material
Implementation Method 2
filling material, in particular with an elastic but incompressible filling material
Implementation Method 3
The filling material can prevent the tension member strands from moving laterally during the pressing process
Implementation Method 4
The filling material can protect the tension member strands from corrosion
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for manufacturing a carcass (24), in particular for use in a belt (2) or belt segment (2), said method involving the step of: preparing a carcass (24) that has a plurality of carcass strands (26). The method is characterized in that at least a portion of the spaces between the carcass strands (26) is filled with a filling material (28) at least at an open end (25) of the carcass (24), the carcass (24) remaining free of filling material (28) on the outside.