Polyamide Cord Endless Flat Belt for Stable Twist Travel
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Solution Overview
Problem
Existing endless flat belts used for twist travel, such as paper tube winding, face issues with breakage due to stress concentration at joints, uneven winding pressure, and one-sided elongation, leading to instability and short service life, especially when manufactured without cylindrical metal molds for varying lengths.
Innovation Solution
An endless flat belt design featuring a polyamide fiber cord core buried in an inner rubber layer, with specific modulus of elasticity values for the cord core and reinforcement fabric, allowing for stable tension and performance during twist travel, and a method to manufacture belts of various lengths without cylindrical metal molds by connecting reinforcement fabric ends and applying vulcanization molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If adhesive is used to join belt ends, then the belt can be made endless, but the joint part hardens and stress concentration occurs leading to breakage
Solution Approach 1:
The patent removes the adhesive joint from the belt structure entirely by using a continuous loop design where the belt ends are joined through the molding process itself rather than post-assembly adhesive bonding. This eliminates the hardened joint portion that causes stress concentration and breakage.
Solution Approach 2:
The belt is molded as a continuous loop from the beginning, with the end portions connected through the molding process itself rather than requiring post-manufacturing assembly. This preliminary formation of the endless structure prevents the creation of weak joint sections.
2Reliability
If belt tension is increased to eliminate uneven winding pressure, then winding performance improves, but belt wear increases and service life decreases
Solution Approach 1:
The patent creates different structural zones within the belt: the inner rubber layer with cord core provides high tensile strength for tension resistance, while the reinforcement fabric layers provide surface durability for wear resistance. This local differentiation allows the belt to handle high tension without increasing overall wear.
Solution Approach 2:
The belt uses a composite structure combining rubber material with reinforcement fabric and cord core. This composite design provides both the tensile strength needed for high tension operation and the surface durability required for extended service life, resolving the contradiction between winding performance and service life.
3Reliability
If strong winding is applied to eliminate uneven pressure, then winding performance improves, but power consumption increases and mandrel wear increases
Solution Approach 1:
The patent changes the physical parameters of the belt by optimizing the modulus of elasticity of the cord core (10-200 MPa) and reinforcement fabric to achieve the right balance between flexibility for easy winding and strength for maintaining tension. This allows effective winding performance with reduced power consumption.
4Ease of operation
If belt is softened to improve winding performance, then flexibility improves, but deformation volume increases leading to uneven wear
Solution Approach 1:
The belt structure differentiates between the inner rubber layer containing the cord core, which provides flexibility and elastic recovery to prevent permanent deformation, and the outer reinforcement fabric layers that maintain shape stability. This local functional differentiation resolves the contradiction between flexibility and shape retention.
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 solution stabilizes belt tension and performance, prevents breakage and one-sided elongation, ensures longer service life, and allows for easy production of belts with large circumferential lengths, while maintaining rigidity and equalizing winding pressure.
Implementation Method 1
a cord core which is wound spirally at a predetermined pitch in a width direction of the endless flat belt
Implementation Method 2
a reinforcement fabric stuck to one surface of the inner rubber layer
Implementation Method 3
applying vulcanization molding
Data Source
Figure 1~4
Figure 5(a)~6
Figure 7(a)~8
AI summary
An endless flat belt includes an inner rubber layer 1, a cord core 11 buried in the inner rubber layer 1 and spirally wound at a predetermined pitch in a width direction of the belt, and a reinforcement fabric 2 stuck to the inner rubber layer 1. The cord core comprises polyamide fiber. Opposite ends of the reinforcement fabric 2 are connected with each other into an endless form by adhesion or sewing. A surface rubber layer 3 is stuck to a surface of the reinforcement fabric 2 which is opposite a surface thereof stuck to the inner rubber layer 1.