Layered V-Belt Hardness Gradient for Crack and Buckling Resistance
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Solution Overview
Problem
Existing power transmission V-belts, particularly variable speed belts, face challenges in balancing durability and fuel consumption saving, especially under high-load conditions, where reduced thickness leads to increased susceptibility to buckling deformation, vibration-induced cracking, and interlayer separation.
Innovation Solution
The power transmission V-belt design features a tension member embedded in an adhesion rubber layer with a layered structure of tension and compression rubber layers, where the rubber hardness of the tension rubber layer is lower than the compression rubber layer, and the adhesion rubber layer's hardness is adjusted stepwise to ensure lateral pressure resistance and prevent interlayer separation and cracking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the belt thickness is reduced to save fuel and reduce weight, then fuel consumption saving is improved, but the belt becomes more susceptible to buckling deformation, vibration-induced cracking, and interlayer separation under high-load conditions
Solution Approach 1:
The belt employs a composite structure with multiple rubber layers (tension rubber layer, adhesion rubber layer, compression rubber layer) each having different hardness characteristics. This composite material approach allows the belt to maintain reduced thickness for fuel efficiency while the layered composite structure provides enhanced resistance to buckling deformation, vibration-induced cracking, and interlayer separation under high-load conditions.
Solution Approach 2:
The invention applies local quality by creating a hardness gradient within the adhesion rubber layer, where the hardness varies from the tension rubber layer side to the compression rubber layer side. This localized variation in material property allows different regions of the belt to perform different functions: softer regions near the tension layer absorb vibrations and prevent cracking, while harder regions near the compression layer resist buckling deformation, all within a thin belt structure.
2Reliability
If the rubber hardness of the tension rubber layer is made lower to prevent cracking, then resistance to vibration-induced cracking is improved, but the overall structural stability under lateral pressure may be compromised
Solution Approach 1:
The invention resolves this contradiction by implementing local quality through a hardness gradient in the adhesion rubber layer. The tension rubber layer has lower hardness (80-90 degrees) to resist vibration-induced cracking, while the compression rubber layer has higher hardness (90-100 degrees) to maintain structural stability under lateral pressure. The adhesion rubber layer's hardness transitions gradually between these two layers, ensuring both cracking resistance and structural integrity.
Solution Approach 2:
The multi-layer composite structure with differentiated hardness characteristics allows each layer to specialize in specific functions. The tension rubber layer with lower hardness prevents cracking under vibration, while the compression rubber layer with higher hardness provides structural stability under lateral pressure, and the adhesion layer with gradient hardness bonds them effectively, resolving the contradiction between cracking resistance and structural stability.
3Ease of manufacture
If the adhesion rubber layer has uniform hardness to simplify manufacturing, then manufacturing complexity is reduced, but the belt is more prone to interlayer separation under severe loading conditions
Solution Approach 1:
The invention applies local quality by creating a hardness gradient within the adhesion rubber layer, where hardness varies from the tension rubber layer side to the compression rubber layer side. This localized variation in material property allows different regions of the adhesion layer to perform different functions: softer regions provide better bonding to the tension layer to prevent separation, while harder regions provide structural support, thereby preventing interlayer separation under severe loading conditions.
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 achieves both durability and fuel consumption saving by reducing the likelihood of cracking and interfacial separation, even when the belt is compact, effectively maintaining performance under severe high-load conditions.
Implementation Method 1
an adhesion rubber layer in which at least part of the tension member is embedded
Implementation Method 2
the rubber hardness of the tension rubber layer is smaller than the rubber hardness of the compression rubber layer
Data Source
Figure 1(a)~1(b)
Figure 2
Figure 3
AI summary
The present invention is a transmission v-belt (1) that is provided with a core (4a), an adhesive rubber layer (4) in which at least a part of the core (4a) is embedded, and an expansion rubber layer (3) and a compression rubber layer (5) that are layered with the adhesive rubber layer (4) therebetween, and pertains to the transmission v-belt (1) wherein the rubber hardness of the expansion rubber layer (3) is less than the rubber hardness of the compression rubber layer (5), and the rubber hardness of the adhesive rubber layer (4) closer to the expansion rubber layer side than the core is less than the rubber hardness of same closer to the compression rubber layer side.