Thermal Impulse Welding Profiles to Conveyor Belts
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Solution Overview
Problem
Existing methods for welding profiles to conveyor belts are limited, particularly for materials of low permittivity like polyolefins, and often require expensive and complex high-frequency welding equipment.
Innovation Solution
A process using thermal impulse heating to weld profiles to conveyor belts, where heat is applied to one surface of the belt opposite to where the profile is attached, allowing for efficient bonding even with low permittivity materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high frequency welding is used to weld profiles to conveyor belts, then strong bonding is achieved, but the equipment becomes expensive and difficult to handle
Solution Approach 1:
The patent replaces the complex high-frequency electromagnetic welding system with a simpler thermal impulse welding system. Instead of using electromagnetic fields to generate heat through dielectric heating, the invention uses a heated tool that directly transfers thermal energy to the plastic materials, achieving strong bonds without requiring expensive HF welding equipment
Solution Approach 2:
The patent introduces a heated tool as an intermediary between the heat source and the plastic materials. This tool, which can be made of metal or ceramic, is heated to a controlled temperature and then pressed against the profile and belt surface, transferring heat locally to create strong bonds without needing complex electromagnetic field generation equipment
2Strength
If high frequency welding is used, then strong bonding is achieved, but the equipment cost increases
Solution Approach 1:
The patent employs a relatively simple and inexpensive heated tool that can be easily manufactured and replaced if needed. This tool serves as a cost-effective alternative to expensive high-frequency welding equipment, achieving the same bonding strength without the high capital investment required for HF welding systems
Solution Approach 2:
The invention substitutes the expensive electromagnetic field-based heating system with a straightforward thermal conduction system using a heated tool. This replacement dramatically reduces equipment costs while maintaining effective welding capability for plastic profiles to conveyor belts
3Adaptability or versatility
If thermal impulse welding is applied to low permittivity materials like polyolefins, then welding becomes feasible, but heat must be applied through the belt thickness
Solution Approach 1:
The patent applies heat to the opposite side of the belt from where the profile is being welded. By heating the pulley side (opposing surface) rather than the conveying side, thermal energy conducts through the belt thickness to the profile interface, enabling welding of low permittivity materials like polyolefins that cannot be effectively welded using high-frequency methods
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 provides strong and reliable adhesion of profiles to conveyor belts, suitable for various belt materials, including polyolefins, without the need for expensive high-frequency welding equipment.
Implementation Method 1
thermal impulse heating; heat is intermittently created by an electrical current in a high electrical resistance conductor
Implementation Method 2
the welding heat is applied by thermal impulse heating; heat is applied to one surface of the belt opposite to where the profile is attached
Data Source
Figure 1a~1e
Figure 2
AI summary
A process for welding profiles (1) of a thermoplastic or thermoplastic elastomer to a top layer (3) of a belt (2), such as a conveyor belt, also being made of a thermoplastic or thermoplastic elastomer. The process uses thermal impulse welding and applies the welding heat onto the surface (21) of the belt (2) which is opposite to the top layer (3). The process is in particular suited for welding TPO profiles to TPO top layers.