Thin Wear-Resistant Belt for Two-Drum Winder
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Solution Overview
Problem
In two-drum winders, the existing belts for belt drums experience significant slippage and wear due to bending during the winding process, leading to uneven thickness and winding issues, primarily because the distance between the support layer and the outer surface is too great, causing excessive stress and wear on the belt surface.
Innovation Solution
The belt features a thin, highly wear-resistant outer layer made of materials like rubber or polyurethane elastomer, with a support layer close to the outer surface, eliminating the need for a separate transverse stiffening layer, thereby reducing the distance between the support layer and the outer surface, minimizing stress and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the distance between the support layer and the outer surface of the belt is great, then the belt has sufficient structural stability and strength, but the bending during winding causes excessive stretch and slippage leading to wear and thickness variations
Solution Approach 1:
The invention changes the critical parameter of the distance between the support layer and the outer surface from a large value (prior art) to a small value (maximum 3.5 mm when new). This parameter change reduces the stretch during bending while the high wear-resistant material compensates for the reduced thickness, resolving the contradiction between structural stability and winding reliability.
Solution Approach 2:
The invention uses composite materials combining a support layer (carrying tensile stress) with a thin outer layer of highly wear-resistant material (rubber or polyurethane elastomer). This composite structure provides both the structural stability needed for strength and the wear resistance needed for reliable winding, allowing the outer layer to be thin without compromising overall belt performance.
2Duration of action of moving object
If the outer layer of the belt is made thick to provide sufficient wear resistance, then the belt has longer service life, but the stretch during bending increases causing slippage and wear
Solution Approach 1:
The invention changes the material parameter of the outer layer from conventional rubber to highly wear-resistant rubber or polyurethane elastomer. This material parameter change allows the outer layer to be thin (maximum 3.5 mm) while maintaining high wear resistance, eliminating the need for thick layers that cause excessive stretch and slippage during bending.
Solution Approach 2:
The invention applies local quality by making the outer layer thin (maximum 3.5 mm) while using highly wear-resistant material specifically at the contact surface. This localized optimization provides sufficient wear resistance without the harmful effects of thick layers, reducing slippage and wear during the winding process.
3Stability of the object's composition
If a separate transverse stiffening layer is added to stabilize the belt width, then the belt has better width stability, but the distance between the support layer and outer surface increases causing more stretch and wear
Solution Approach 1:
The invention merges the functions of the support layer and transverse stiffening layer by incorporating transverse yarns directly into the support layer. This combination eliminates the need for a separate stiffening layer, maintaining belt width stability while keeping the distance between the support layer and outer surface small, thus reducing stretch and wear during winding.
Solution Approach 2:
The invention creates a composite support layer containing both longitudinal yarns (for tensile strength) and transverse yarns (for width stability). This integrated composite structure provides both width stabilization and support functions in one layer, avoiding the need for additional layers that would increase the distance to the outer surface and cause excessive stretch.
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 design significantly reduces slippage, wear, and thickness variations, extending the belt's service life and maintaining even thickness, while enhancing fatigue durability and minimizing disturbances during the winding process.
Implementation Method 1
the outer layer which is composed of an elastic, resilient wear-resistant material, such as rubber, polyurethane elastomer or another elastomer
Data Source
Figure 1~3
AI summary
The invention relates to a belt for a set of belt drums in a two-drum winder, which belt (20) comprises a support layer (21) that maintains the longitudinal tension of the belt (20), an outer layer (22) between the support layer (21) and an outer surface (23) of the belt (20) placed against a fibrous web roll (10) that is being wound on the two-drum winder, and an inner layer (25) between the support layer (21) and a surface placed against lead rolls (12, 13) of the set of belt drums (15) in the two-drum winder. The outer layer (22) of the belt (20) is thin, i.e. has a thickness of less than 3.5 mm when the belt is new and unused, and the outer layer of the belt (20) is manufactured of a wear-resistant material, such as rubber or elastomer.