Segmented Endless Belt with Coated Carrier Structure
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Solution Overview
Problem
Existing endless belts with polymer coatings are limited in width by the maximum coating width of available machines, restricting their application in wider machines, and current methods for producing wider belts are complex and inefficient.
Innovation Solution
The belt is composed of multiple segments with individual carrier structures and coatings, connected via transverse seams, allowing each segment to be coated in a single pass and assembled to achieve any desired width, using various fabric types and seam configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single continuous belt is coated using conventional coating machines, then the coating can be applied uniformly, but the belt width is limited to the maximum coating width of the machine (6m)
Solution Approach 1:
The belt is divided into multiple individual belt segments (first belt segment, second belt segment, etc.) that are coated separately using conventional coating machines, then connected together via seams to form a continuous endless belt. This allows each segment to be within the coating machine's width capability while the final assembled belt exceeds this limitation.
2Area of stationary object
If the belt is assembled from multiple segments connected by seams, then the belt can achieve greater width, but the seam integrity must be maintained under operational stresses
Solution Approach 1:
The belt segments are pre-coated individually before assembly, ensuring each segment has its coating applied under controlled conditions. The coating process is completed on each segment separately, then the segments are connected via seams to form the final wide belt structure.
3Productivity
If conventional coating machines are used, then the coating can be applied in a single pass, but the maximum belt width is restricted to 6m
Solution Approach 1:
The coating process is segmented across multiple belt segments that are coated individually using conventional machines operating at full efficiency, then assembled together. This maintains the productivity benefit of single-pass coating while achieving widths beyond what a single machine can handle.
4Area of stationary object
If spiral winding technique is used to create wide belts, then belts wider than 6m can be produced, but the process becomes complex
Solution Approach 1:
Instead of using complex spiral winding, the belt is segmented into multiple rectangular segments that are coated using conventional linear coating processes, then assembled in a straightforward manner using standard seam connection techniques, thereby avoiding the complexity of spiral winding equipment.
Data Source
Figure 1~2
Figure 3
AI summary
The belt (1) has multiple belt segments (2-7) assembled one behind the other in a continuous direction (A) and comprising respective carrier structure segments (8-13) e.g. threads containing sheets, are provided with coatings (14-19). Extension of the belt segments and the carrier structure segments in a transverse direction vertical to the continuous direction corresponds to extension of the belt in the vertical transverse direction. The belt segments are connected with each other through seams (20-25) extending in the transverse direction. The coating comprises fabric threads, monofilaments, multi-filaments, and spun fiber yarns and/or threads.