Thermoplastic Spindle Tape Edges Sealed by Ultrasound or Laser
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing conveyor belts and machine tapes with knife-cut or punched edges tend to fray and absorb dirt and moisture due to cut filament ends, and methods like ultrasound or laser cutting often result in bulged-up edges or inadequate sealing.
Innovation Solution
A belt with ultrasound-cut or laser-cut lateral edges, featuring a thermoplastic textile layer and a thermoplastic or thermoplastic elastomer coating, which seals the edges by partial melting, preventing fraying and moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If knife cutting or punching is used to cut conveyor belts, then the cutting process is simple and fast, but the edges produce cut filament ends that are prone to fraying and picking up dirt and moisture
Solution Approach 1:
The patent changes the cutting method from mechanical (knife/punching) to thermal (ultrasound/laser), fundamentally altering the cutting parameters to achieve sealed edges without fraying while maintaining manufacturing efficiency
Solution Approach 2:
The patent replaces mechanical cutting systems with thermal cutting systems (ultrasound or laser), substituting mechanical force with thermal energy to seal and fuse the edge filaments, preventing fraying and contamination
2Reliability
If ultrasound cutting is used to cut conveyor belts, then the edges are sealed and non-fraying, but the edges tend to bulge up and have greater thickness near the cut edge
Solution Approach 1:
The patent optimizes ultrasound cutting parameters including frequency (20-100 kHz), power (100-500 W), and advancing speed (1-10 m/min) to control the degree of melting and sealing while minimizing bulge formation, achieving a balance between edge sealing and flatness
Solution Approach 2:
The patent applies partial melting rather than complete melting of the edge material, using controlled ultrasound energy to seal the filaments just enough to prevent fraying while avoiding excessive material displacement that causes bulging
3Reliability
If laser cutting is used to cut conveyor belts, then the edges are sealed and non-fraying, but the edges may be blackened and have inadequate sealing durability
Solution Approach 1:
The patent optimizes laser cutting parameters including power (50-200 W), wavelength (CO2 laser at 10.6 μm or fiber laser), and advancing speed (1-10 m/min) to achieve clean sealing of edges while minimizing carbonization and blackening through controlled thermal input
Solution Approach 2:
The patent uses high-speed laser cutting to rapidly pass through the material with controlled energy input, sealing the edges before excessive heat accumulation can cause blackening, thereby achieving clean sealed edges with improved aesthetic appearance
4Reliability
If thermoplastic coating layer is applied and ultrasound cutting is used, then the edges are well sealed and non-fraying, but the manufacturing process becomes more complex
Solution Approach 1:
The patent combines the coating application and cutting processes into an integrated manufacturing flow, where the thermoplastic coating is applied to the conveyor belt and then ultrasound cutting is performed in a coordinated manner to seal the edges, merging two operations into a cohesive process that achieves superior sealing while managing complexity through integration
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 belt achieves non-fraying edges with a thickness similar to the bulk of the belt, enhancing durability and resistance to environmental contaminants, while being easier to produce than prior art commercial belts.
Implementation Method 1
the lateral edges are ultrasound-cut or laser-cut
Implementation Method 2
the lateral edges are ultrasound-cut or laser-cut
Implementation Method 3
the cut edges so produced are molten to at least in part
Data Source
AI summary
A conveyor belt, power transmission belt or machine tape (1) being open-ended with two ending edges (6, 7) and with a longitudinal length (L) in a longitudinal direction, comprising: a) two parallel lateral edges (1a, 1b) running in said longitudinal direction, and being spaced apart from each other by a transversal width (W); b) a first textile layer (2); c) a first coating layer (3); and optionally d) one more through holes (5) perforating the belt through its overall thickness (T), each of these through holes (5) being formed by a hole edge (5a); characterized in that i) the first textile layer (2) comprises fibres or filaments of a thermoplastic and/or the first coating layer (3) comprises a thermoplastic or thermoplastic elastomer; and ii) the lateral edges (1a, 1b) are ultrasound-cut or laser-cut and/or the optional hole edge(s) (5a) is(are) laser-cut. The belt or tape has melt-sealed edges, can be made endless by conventional end-joining and can be used in fluff-generating environments, such as a spindle tape.