Segmented Belt Shaping Body With Induction Vulcanization
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Solution Overview
Problem
Existing drive belt manufacturing processes face limitations such as high personnel costs, capital expenditure for pressure vessels, and length restrictions, particularly for small coils, leading to inefficient and costly production of V-ribbed belts.
Innovation Solution
A manufacturing apparatus with a tubular shaping body divided into sectors, locked against axial movement, and housed within an outer tube, allowing for uniform temperature distribution and easy demolding, using induction heating and a flexible pressure bellows to form and vulcanize the drive belt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a steel mold is designed as a double-walled pressure vessel for steam heating, then vulcanization can be performed, but capital expenditure and personnel costs increase significantly
Solution Approach 1:
The patent replaces the mechanical steam heating system (double-walled pressure vessel) with an induction heating system using electromagnetic fields. The shaping body is made of ferromagnetic material that can be directly heated by induction, eliminating the need for complex steam infrastructure while maintaining vulcanization capability
Solution Approach 2:
The patent uses pressurized gas (nitrogen or air) instead of steam for heating and vulcanization. The gas is circulated through channels in the shaping body, providing both heating and vulcanization functions without requiring a double-walled pressure vessel design
2Manufacturing precision
If the shaping body is made as a single piece, then manufacturing precision is maintained, but demolding becomes difficult for short belts
Solution Approach 1:
The shaping body is divided into multiple separable parts (first shaping body and second shaping body) that can be detached from each other. This allows the drive belt to be easily removed after vulcanization while each part maintains sufficient precision for proper shaping. The segments can be locked together during forming and separated for demolding
3Ease of manufacture
If the shaping body is divided into separable parts, then demolding becomes easier, but temperature uniformity during vulcanization deteriorates
Solution Approach 1:
The gas circulation system serves multiple functions: it heats the shaping body uniformly, provides vulcanization atmosphere, and can be adjusted for different production scenarios. The same gas channels that distribute heat also facilitate uniform temperature distribution across all shaping body parts during vulcanization
Solution Approach 2:
The gas circulation operates continuously throughout the vulcanization process, maintaining constant temperature and pressure conditions. The pressurized gas flows continuously through the shaping body channels, ensuring uniform heat distribution and preventing temperature gradients that would occur with intermittent heating
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
Enables efficient production of drive belts of various lengths with reduced infrastructure costs, minimal wear, and uniform temperature control, facilitating global distribution and production of specialized belts.
Implementation Method 1
the shaping body (2, 3) is made of a ferromagnetic material and can be heated by induction heating in a uniform manner
Implementation Method 2
pressurizing an inner space of the pressure bellows for performing a pressing operation of the coil blank (40) against the shaping surface (6)
Data Source
AI summary
The invention relates to an apparatus for manufacturing at least one drive belt, comprising a tubular shaping body having a first inner cavity which extends in the longitudinal direction of the shaping body over the entire or predominant length of the shaping body and is surrounded circumferentially by a wall of the shaping body, wherein the inner side of the wall of the shaping body facing the first inner cavity has a shaping surface for abutment and shaping of the drive belt to be produced during the manufacturing process. The invention also relates to a method of manufacturing at least one such drive belt by means of such an apparatus.