Foamed Polymer Conveyor Belt Cleats for Weight Reduction
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Solution Overview
Problem
Conveyor systems with corrugated edges and cleats are heavy and costly due to their material composition, leading to high energy consumption and operational expenses.
Innovation Solution
Incorporating a foamed polymer mixture into at least one side wall and/or cleat of the conveyor belt, which can be layered with non-foamed rubber or textile materials, to reduce the total weight while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If corrugated edges and cleats are made from solid polymeric materials, then the conveyor belt provides good lateral seal and prevents material slippage, but the total weight of the conveyor belt increases significantly
Solution Approach 1:
The patent applies porous foam material to replace solid polymeric materials in the side walls and cleats. The foam structure maintains the necessary mechanical properties for sealing and preventing slippage while significantly reducing the density and overall weight of these components. The cellular structure of the foam provides adequate rigidity and friction surfaces for material containment.
Solution Approach 2:
The patent uses composite construction by combining foam material with fabric inserts in the side walls and cleats. This composite approach allows the foam to provide weight reduction and basic structural function, while the fabric reinforcement maintains tensile strength and structural integrity, achieving a balance between weight reduction and functional performance.
2Strength
If solid polymeric materials are used for side walls and cleats, then structural integrity and functional performance are maintained, but material cost increases
Solution Approach 1:
The foam material provides structural integrity with reduced material quantity. The cellular structure of the foam maintains adequate strength and stiffness while using less polymer material compared to solid construction, directly reducing material costs.
Solution Approach 2:
The composite of foam and fabric creates a structurally sound component using less expensive foam material as the primary structure, with fabric providing reinforcement only where mechanically necessary, optimizing the balance between strength and material cost.
3Use of energy by moving object
If the conveyor belt weight is reduced using foamed polymer mixtures, then energy consumption decreases, but manufacturing complexity increases due to foaming process
Solution Approach 1:
The patent changes the physical state of the polymer material from solid to foamed structure. This parameter change in material density and structure achieves weight reduction for lower operational energy consumption, while the foaming process is integrated into existing manufacturing workflows.
Solution Approach 2:
The composite manufacturing approach combines foam material processing with fabric insert integration, utilizing established composite manufacturing techniques that balance the added complexity of foaming with proven fabrication methods for layered structures.
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 use of foamed polymer mixtures significantly reduces the weight of the conveyor belt, achieving cost optimization and lower energy consumption without compromising the conveyor system's functionality.
Implementation Method 1
it has surprisingly been found that the total weight of the conveyor belt can be significantly reduced if at least one side wall and / or at least one cleat each contains at least one foamed polymer mixture
Data Source
Figure 1A~2
Figure 3a~3d
AI summary
The invention relates to a conveying installation having a conveying belt, comprising at least one side wall, constructed from in each case one polymer material with elastic properties, and/or at least one cleat, constructed from in each case one polymer material with elastic properties, and also having drums, load‑bearing rollers and load‑bearing frameworks, wherein the conveying installation forms a material‑conveying upper strand, with a supply location for the conveying material, and an at least material‑free lower strand. The conveying installation according to the invention is distinguished in that at least one side wall and/or at least one cleat of the conveying belt contain/contains at least one foamed polymer mix.