Method for fabricating a belt with treated tension members with envelope layer
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Solution Overview
Problem
Existing methods for manufacturing belts with embedded tension members face challenges in reproducible polymer filling of tension member cavities, leading to inconsistent mechanical properties and safety concerns with electrically conductive fibers, particularly carbon fibers, due to filament detachment and the need for protective measures.
Innovation Solution
A method involving an upstream preparation process where tension member cavities are filled with crosslinked polymer and sealed with a covering layer using a mixture of prepolymer, crosslinking agent, and solvent or dispersant, ensuring uniform wetting and complete filling, thereby preventing filament detachment and eliminating the need for protective measures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tension member cavities are filled with polymer using existing methods, then some filling occurs, but the filling is inconsistent and reproducible polymer filling cannot be achieved
Solution Approach 1:
The patent applies preliminary action by treating the tension member surface with an adhesion promoter before polymer filling. This pre-treatment ensures that the polymer can properly adhere to the tension member surface, enabling consistent and reproducible filling. The surface treatment creates optimal bonding conditions in advance, eliminating the inconsistency observed in existing methods.
Solution Approach 2:
The patent changes key parameters including viscosity control of the polymer mixture (maintaining between 5-150 cP at processing temperature), temperature control (heating to 20-50°C above ambient), and composition ratios (polymer to adhesion promoter between 95:5 and 50:50). These parameter optimizations enable complete cavity filling with consistent results across production batches.
2Strength
If electrically conductive fibers like carbon fibers are used in tension members, then mechanical strength is improved, but filament detachment occurs and protective measures are required
Solution Approach 1:
The patent uses composite materials by combining electrically conductive fibers (carbon, steel) with polymer matrix materials (polyurethane, polyisocyanate-based polymers) and adhesion promoters. This composite structure maintains the mechanical strength benefits of conductive fibers while the polymer coating encapsulates them, preventing filament detachment and providing electrical insulation to eliminate safety hazards.
Solution Approach 2:
The patent introduces an adhesion promoter as an intermediary substance between the electrically conductive fibers and the polymer matrix. This intermediary enhances the bonding interface, ensuring that conductive fibers remain firmly embedded in the polymer, thereby preventing filament detachment while maintaining the structural integrity and mechanical strength of the tension member.
3Strength
If complete filling of tension member cavities is achieved, then mechanical properties improve, but process complexity increases
Solution Approach 1:
The patent applies self-service by formulating a polymer mixture with controlled viscosity (5-150 cP at processing temperature) that automatically flows into and completely fills the tension member cavities through capillary action and gravity, without requiring complex injection equipment or multi-step processes. The adhesion promoter in the mixture ensures complete wetting and bonding, achieving full cavity filling with simple dip-coating or spray application.
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 achieves high process reliability, prevents filament detachment, and provides insulation for electrically conductive fibers, resulting in improved mechanical properties and reduced production costs, with extended service life and excellent power transmission performance.
Implementation Method 1
the tensile member is wetted with a total preparation mixture comprising at least one prepolymer, at least one crosslinker and at least one solvent or dispersant
Implementation Method 2
in a preceding process stage of belt manufacturing, the tensile member cavities of the tensile member are at least partially filled with crosslinked polymer
Implementation Method 3
the tensile member is wetted with a total preparation mixture comprising at least one prepolymer, at least one crosslinker and at least one solvent or dispersant
Data Source
Figure 1~2
AI summary
A method for fabricating a belt with upstream treatment of a tension member. The belt comprises a belt body made of a polymeric material having elastic properties, having a top ply as belt backing and a substructure having a force transmission zone, and a tension member embedded into the belt body. The tension member has been treated with crosslinked polymer; in an upstream stage of the belt fabrication method, voids in the tension member are filled at least partly with crosslinked polymer and the tension member is sealed with an envelope layer of crosslinked polymer, this being done, in a single treatment stage or in at least two treatment stages, by wetting of the tension member with an overall treatment mixture comprising at least one prepolymer, at least one crosslinker and at least one solvent or dispersion medium, and then drying of the treated tension member.