Steel Cable Rubberization via Wire Coating
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Solution Overview
Problem
Conveyor belts with steel cable constructions face challenges in achieving full rubberization, leading to open cavities that allow liquid migration and corrosion, especially in closed cable constructions where complete penetration is difficult.
Innovation Solution
Applying a coating agent to at least 50% of the individual wires before or during twisting in a stranding machine to form a strand, ensuring complete rubberization of the cable by uniformly distributing the coating agent throughout the cable construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive rubber mixtures are used to optimize adhesion and flow into steel cables during vulcanization, then adhesion is improved, but complete penetration through the entire cable becomes difficult especially in closed cable constructions
Solution Approach 1:
The patent applies preliminary action by coating the individual steel wires with a lubricant before they are stranded into cables. This pre-coating ensures that the adhesive rubber mixture can penetrate through the cable construction during vulcanization, as the lubricant creates pathways and reduces friction between wires. This resolves the contradiction by preparing the cable structure in advance to facilitate complete penetration while maintaining adhesion.
Solution Approach 2:
The patent utilizes porous materials by creating a lubricant-coated surface layer on the steel wires that allows the adhesive rubber mixture to penetrate through. The lubricant forms a porous or permeable barrier that enables fluid passage while maintaining structural integrity, thus achieving complete penetration in closed cable constructions without compromising adhesion.
2Object-affected harmful factors
If steel cables are galvanized to prevent corrosion, then corrosion resistance is improved, but adhesion of adhesive rubber mixtures deteriorates
Solution Approach 1:
The patent applies local quality by using different surface treatments on different parts of the steel cable structure. The individual wires are coated with a lubricant that promotes adhesion, while the overall cable structure can be galvanized for corrosion resistance. This localized differentiation allows both adhesion and corrosion resistance to coexist by applying appropriate treatments to specific locations and components.
Solution Approach 2:
The patent uses composite materials by combining galvanized steel wires with an additional lubricant coating. The galvanization layer provides corrosion resistance while the lubricant coating provides adhesion promotion. This composite structure integrates two materials with complementary properties, resolving the contradiction between corrosion resistance and adhesion.
3Manufacturing precision
If complex production methods are used to form additional microgaps for rubberization mass entry, then complete rubberization is improved, but device complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-coating the steel wires with lubricant before stranding, which creates the necessary pathways for rubberization mass entry. This eliminates the need for complex post-production methods to create microgaps, as the lubricant coating itself facilitates rubber penetration during standard vulcanization processes, thereby reducing device complexity while achieving complete rubberization.
Solution Approach 2:
The patent extracts the function of creating penetration pathways from the complex production method and transfers it to a simple pre-coating process. By removing the need for complex microgap formation equipment and processes, the invention simplifies the production system while maintaining complete rubberization capability through the lubricant-coated wire structure.
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 ensures complete rubberization of the cable, reducing open cavities and preventing liquid migration, thereby enhancing the durability and longevity of the conveyor belt by ensuring effective sealing and corrosion resistance.
Implementation Method 1
applying at least one coating agent partially or completely in each case to at least 50% of the individual wires prior to twisting the individual wires to form a strand
Implementation Method 2
twisting the individual wires to form a strand
Data Source
AI summary
The invention relates to a method for filling in a tension member in particular for conveyor belts, in particular a tension member which is configured as a steel cable. The method is intended to allow the full penetration of the tension member structure. Here, the method contains at least the following method steps: —introducing the individual wires (2, 2′, 2″, 2′″, 2″″) of the strand (5) into the stranding head (1) of a stranding machine (10) and —partially or fully applying at least one coating agent to at least 50% of the individual wires (2, 2′, 2″, 2′″, 2″″) of the strand (5) prior to the twisting of the individual wires (2, 2′, 2″, 2′″, 2″″) to form a strand (5) or simultaneously with the twisting of the individual wires (2, 2′, 2″, 2′″, 2″″) to form a strand (5) and —twisting the individual wires (2, 2′, 2″, 2′″, 2″″) to form a strand (5), wherein at least 50% of the individual wires (2, 2′, 2″, 2′″, 2″″) have been provided with at least one coating agent, and —making a cable from at least one strand (5).