Thermoplastic Elevator Belt Laminate Design
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Solution Overview
Problem
Conventional elevator belts face manufacturing challenges and durability issues due to the use of thermoset resins and rigid carbon fiber composite cords, which result in long curing cycles and air void entrapment, and fail to provide the desired flexibility and resistance to bending cycles.
Innovation Solution
A belt construction using a laminate design with tension elements like steel cords, carbon fiber, or glass fibers enclosed in a matrix material, where inner and outer layers are thermally bonded to enhance properties such as abrasive resistance, and additional layers provide moisture, UV, or fire resistance, with embedded sensors for health monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermoset resin and carbon fiber composite cords are used to provide higher strength to weight ratio, then strength and weight performance are improved, but manufacturing complexity and production time increase due to long curing cycles and air void entrapment
Solution Approach 1:
The patent changes the material parameter from thermoset resin to thermoplastic polymer, which fundamentally alters the manufacturing process from curing to melting and bonding. This parameter change eliminates the long curing cycles and air void entrapment issues while maintaining the high strength-to-weight ratio benefits of carbon fiber reinforcement.
Solution Approach 2:
The patent uses composite construction by combining thermoplastic polymer matrix with carbon fiber or other reinforcement elements. This composite approach provides the high strength-to-weight ratio needed for elevator belts while the thermoplastic matrix enables simpler manufacturing compared to thermoset systems.
2Strength
If thermoset resin and rigid carbon fiber composite cords are used to provide higher strength, then tensile strength is improved, but flexibility and durability deteriorate due to rigid construction and brittleness
Solution Approach 1:
The patent changes the material parameter from rigid thermoset resin to flexible thermoplastic polymer, which fundamentally alters the mechanical properties. This parameter change allows the belt to maintain high tensile strength through fiber reinforcement while gaining the flexibility needed for bending cycles and elevator operation.
Solution Approach 2:
The patent creates a dynamic material system where the thermoplastic polymer can deform and flex under stress, unlike rigid thermoset composites. This dynamic characteristic allows the belt to accommodate bending cycles and operational stresses while maintaining structural integrity through the reinforcement elements.
3Stability of the object's composition
If thermoset resin is used for manufacturing composite cords, then structural stability is improved, but production time increases due to long curing cycles
Solution Approach 1:
The patent changes the material parameter from thermoset resin to thermoplastic polymer, which fundamentally alters the processing mechanism from chemical curing to physical melting and bonding. This parameter change eliminates the long curing cycles while maintaining structural stability through the crystalline or semi-crystalline structure of the thermoplastic material.
4Ease of manufacture
If conventional steel cords are used for tension support, then manufacturing simplicity is maintained, but strength to weight ratio and performance deteriorate
Solution Approach 1:
The patent uses composite construction by combining thermoplastic polymer matrix with carbon fiber or other high-performance reinforcement elements. This composite approach provides superior strength-to-weight ratio compared to conventional steel cords while the thermoplastic processing maintains manufacturing simplicity.
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 solution provides a flexible and durable elevator belt with improved strength-to-weight ratio, reduced manufacturing costs, and enhanced performance by allowing tailored material selection for specific requirements, while ensuring smooth operation and extended belt life.
Implementation Method 1
The plurality of tension elements are at least partially enclosed in a matrix material formed from a thermoplastic polymer
Implementation Method 2
the inner belt layer and/or the outer belt layer are thermally bonded to the plurality of tension elements
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A belt for suspending and/or driving an elevator car extending longitudinally along a length of the belt. An inner belt layer formed from a first material is bonded to the plurality of tension elements at a first side of the belt. The inner belt layer forms an inner belt surface interactive with a traction sheave of an elevator system. An outer belt layer formed from a second material is bonded to the plurality of tension elements at a second side of the belt. The plurality of tension elements are located between the first side and the second side.