Two-Layer V-Ribbed Belt Structure to Prevent Rubber Bleeding
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Solution Overview
Problem
Existing V-ribbed belts face issues with rubber bleeding out to the frictional power transmission surface during the vulcanization process, especially when using cords with high elastic modulus, leading to inadequate sound emission resistance and durability.
Innovation Solution
A V-ribbed belt design featuring a compression rubber layer with a specific Mooney Scorch minimum viscosity for the inner and outer rubber layers, combined with a knitted fabric, prevents rubber bleeding and enhances sound emission resistance, even under high pressure and water exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a cord with high elastic modulus is used to achieve high power transmission capacity, then the power transmission capacity is improved, but rubber bleeding out to the frictional power transmission surface occurs during vulcanization
Solution Approach 1:
The compression rubber layer is divided into two distinct layers: an inner rubber layer with lower Mooney Scorch minimum viscosity (40-90) in contact with the fabric, and an outer rubber layer with higher Mooney Scorch minimum viscosity (50-110). This segmentation allows the inner layer to prevent rubber bleeding through the fabric while the outer layer maintains power transmission properties, resolving the contradiction between using high elastic modulus cords and preventing rubber bleeding.
Solution Approach 2:
Different regions of the compression rubber layer are assigned different viscosity characteristics. The inner rubber layer has lower viscosity to effectively prevent rubber bleeding during vulcanization, while the outer rubber layer has higher viscosity to maintain frictional power transmission capacity. This local differentiation of material properties resolves the contradiction between power transmission and rubber bleeding prevention.
2Strength
If high pressure is applied during vulcanization to ensure proper bonding, then the bonding strength is improved, but rubber bleeding out increases
Solution Approach 1:
The Mooney Scorch minimum viscosity parameter is specifically controlled for each rubber layer to prevent rubber bleeding under vulcanization pressure. The inner rubber layer has viscosity of 40-90 and the outer layer has 50-110, which allows the layers to maintain structural integrity and prevent bleeding even when high pressure is applied during vulcanization for proper bonding.
3Object-generated harmful factors
If the Mooney Scorch minimum viscosity of the rubber composition is increased to prevent rubber bleeding, then rubber bleeding is reduced, but sound emission resistance deteriorates
Solution Approach 1:
The inner rubber layer has lower viscosity (40-90) to maintain sound emission resistance, while the outer rubber layer has higher viscosity (50-110) to prevent rubber bleeding. This local differentiation resolves the contradiction between preventing rubber bleeding and maintaining sound emission resistance, as each layer optimizes for its specific function.
Solution Approach 2:
By segmenting the compression rubber layer into inner and outer layers with different viscosity ranges, the patent allows the inner layer to optimize for sound emission resistance (lower viscosity) while the outer layer optimizes for rubber bleeding prevention (higher viscosity), resolving the contradiction between these two opposing requirements.
4Device complexity
If a single-layer rubber composition is used to simplify the structure, then the device complexity is reduced, but rubber bleeding and sound emission resistance cannot be simultaneously optimized
Solution Approach 1:
The compression rubber layer is segmented into two layers with different viscosity characteristics, which simultaneously optimizes both rubber bleeding prevention and sound emission resistance while maintaining a relatively simple overall structure. This segmentation allows each layer to perform its specific function optimally.
Solution Approach 2:
The patent uses a composite structure of two rubber layers with different Mooney Scorch minimum viscosity ranges. The inner layer (40-90) and outer layer (50-110) work together as a composite system to prevent rubber bleeding and maintain sound emission resistance, achieving superior performance stability compared to a single-layer composition.
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 effectively prevents rubber bleeding, improves sound emission resistance, and maintains durability by using a two-layer rubber composition with specific Mooney Scorch viscosities and a knitted fabric, ensuring accurate rib formation and stable power friction transmission.
Implementation Method 1
the inner rubber layer is formed of a rubber composition having a Mooney Scorch minimum viscosity of 50 to 110 when measured at 125° C., and wherein the outer rubber layer is formed of a rubber composition having a Mooney Scorch minimum viscosity of 70 to 130 when measured at 125° C.
Implementation Method 2
even when a molded body is pressurized and molded in a vulcanization step
Data Source
AI summary
A V-ribbed belt includes a compression rubber layer having a frictional power transmission surface that is covered with a fabric. The compression rubber layer includes an inner rubber layer in contact with the fabric and an outer rubber layer on an outer side of the inner rubber layer. The inner rubber layer is formed of a rubber composition having a Mooney Scorch minimum viscosity of 50 to 110 when measured at 125° C., and the outer rubber layer is formed of a rubber composition having a Mooney Scorch minimum viscosity of 70 to 130 when measured at 125° C.