Welding Shoe Composite for Thermoplastic Belt Seam Quality
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Solution Overview
Problem
Existing welding shoes fail to optimally match heat conduction with desired welding conditions, resulting in unsatisfactory weld seams due to material limitations, leading to issues like buckling and deformation of belts during the welding process.
Innovation Solution
A welding shoe with a plastic-based base material and a material additive that increases thermal conductivity, distributed inhomogeneously in the welding zone, ensuring homogeneous material flow and eliminating the need for additional stabilization, allowing for efficient heat input directly at the weld point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a welding shoe is made from conventional materials (metal, ceramics, or plastics), then it can be produced with standard manufacturing processes, but the heat conduction does not optimally match the desired welding conditions resulting in unsatisfactory weld seams
Solution Approach 1:
The welding shoe is made from a composite material consisting of a plastic-based base material with dispersed metal powder particles. This composite combines the dimensional stability and ease of manufacturing of plastics with the high thermal conductivity of metals, enabling optimal heat conduction for welding while maintaining manufacturability through standard molding processes.
Solution Approach 2:
The metal powder is distributed inhomogeneously within the plastic base material, with higher concentration in the welding zone where heat conduction is most critical. This local quality variation ensures optimal thermal performance at the welding interface while maintaining the overall structural integrity and dimensional stability of the welding shoe.
2Manufacturing precision
If uniform material distribution is used in the welding zone, then the welding shoe is easier to manufacture, but the heat conduction does not optimally match the desired welding conditions
Solution Approach 1:
The metal powder concentration varies spatially within the welding shoe, with higher concentrations positioned in the welding zone to maximize heat conduction where needed. This inhomogeneous distribution optimizes thermal performance without requiring complex manufacturing processes, as the variation can be achieved through standard mixing and molding techniques.
3Productivity
If the welding shoe material has high thermal conductivity, then heat input is efficient, but the material may deform or buckle under welding conditions
Solution Approach 1:
The composite material combines plastic base material providing dimensional stability with metal powder particles providing thermal conductivity. This synergistic combination enables efficient heat transfer for productive welding while the plastic matrix maintains the structural integrity and dimensional stability of the welding shoe under welding conditions.
Solution Approach 2:
The thermal conductivity of the welding shoe is optimized by adjusting the type, amount, and distribution of metal powder particles within the plastic base material. This parameter optimization achieves sufficient heat conduction for efficient welding while maintaining the dimensional stability required to prevent deformation during the welding process.
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 produces strong, homogeneous weld seams with reduced welding time, eliminating the need for rework and stabilizing devices, enabling cost-effective production of endless belts with improved dimensional stability and tensile strength comparable to the rest of the belt.
Implementation Method 1
a material additive that increases the thermal conductivity and is distributed inhomogeneously in at least a partial area of the welding zone
Implementation Method 2
the thermally softened material flows into one another homogeneously and, above all, bubble-free in the welding area due to the pressure of the heating press used
Implementation Method 3
the thermally softened material flows into one another homogeneously
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a welding shoe (1) with a contact surface (2), side surfaces (3), and a rear surface (4), comprising a plastic-based base material (5) with a welding zone (6) for welding an object. According to the invention, at least in a partial area of the welding zone (6), a material additive (7) increasing thermal conductivity is incorporated. Furthermore, the invention includes a welding device (10) which incorporates a welding shoe (1) according to the invention. Another aspect of the invention relates to a method for welding the ends of an object (20) made of a thermoplastic material.