Woven Elevator Belt Multifunctional Coatings
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Solution Overview
Problem
Conventional elevator belt systems face challenges in manufacturing monolithic polymer jackets, particularly when adding fillers for performance enhancements like fire resistance, corrosion resistance, wear resistance, and traction, which can lead to compatibility issues and processing difficulties without compromising traction and durability.
Innovation Solution
A composite fabric system is used, where steel cords are woven with yarns or non-metallic fibers, and an elastomeric binder is applied to provide traction and structural support, with coatings applied to the tension elements, fibers, or between them to enhance protection and performance properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fillers are added to monolithic polymer jacket to enhance performance (fire resistance, corrosion resistance, wear resistance, traction), then performance metrics are improved, but manufacturing complexity and processing difficulty increase
Solution Approach 1:
The patent divides the jacket system into two separate components: a base polymer jacket and separate filler coatings. The filler coatings are applied as distinct layers containing specific fillers (such as metal oxides for fire resistance, corrosion inhibitors, wear particles) rather than mixing fillers into the base polymer. This segmentation allows each component to be optimized independently and simplifies manufacturing by avoiding the need to process complex filled polymer compounds.
Solution Approach 2:
The patent creates a composite structure where a base polymer jacket (providing flexibility and structural integrity) is combined with separate filler-containing coatings (providing specialized performance properties). This composite approach allows the integration of multiple materials with complementary properties without the compatibility issues that arise when mixing fillers into monolithic polymers. The coating system can include multiple layers with different filler types to achieve multiple performance enhancements simultaneously.
2Reliability
If fillers are added to monolithic polymer jacket to enhance performance, then performance metrics are improved, but filler/polymer compatibility issues occur
Solution Approach 1:
The patent separates the filler materials from the base polymer by applying fillers in distinct coating layers rather than mixing them into the polymer matrix. This eliminates compatibility issues because each coating can be formulated with specific binders and dispersants that ensure uniform filler distribution and adhesion to the polymer surface, avoiding the aggregation and incompatibility problems that occur with filled polymers.
Solution Approach 2:
The patent changes the physical state and application method of fillers by transforming them from mixed-phase components in a monolithic polymer to surface-applied coatings. This parameter change allows for better control of filler distribution, concentration, and type in each coating layer, ensuring optimal compatibility and performance without the constraints of polymer-filler interfacial compatibility.
3Ease of manufacture
If composite fabric system is used with separate coatings, then manufacturing challenges are reduced and flexibility is maintained, but device complexity increases
Solution Approach 1:
The patent employs a universal coating system that can provide multiple performance enhancements (fire resistance, corrosion resistance, wear resistance, traction) through a standardized multi-layer coating process. Each coating layer serves multiple potential functions and can be applied using the same general coating equipment and procedures, reducing manufacturing complexity despite the multiple layers. The coating system is designed to be adaptable to different base polymer fabrics without requiring fundamentally different processing approaches.
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 composite fabric system improves traction, corrosion resistance, and durability while maintaining flexibility, addressing manufacturing challenges and ensuring key performance metrics are met, including reduced noise and enhanced mechanical properties.
Implementation Method 1
provides a frictional load path to provide traction for driving the belt
Implementation Method 2
corrosion resistance of 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 includes a plurality of tension elements extending longitudinally along a length of the belt and a plurality of fibers interlaced with the plurality of tension elements forming a composite belt structure. A coating at least partially encapsulates the composite belt structure to improve two or more operational characteristics of the belt. A method of forming a belt for suspending and/or driving an elevator car includes forming a plurality of tension elements and arraying the plurality of tension elements longitudinally along a belt. A plurality of fibers are interlaced with the plurality of tension elements to form a composite belt structure. A coating is applied to at least partially encapsulate the composite belt structure to improve at least two operational characteristics of the belt.