CN109070507A - 制造多层热塑性传送带的方法 - Google Patents
制造多层热塑性传送带的方法 Download PDFInfo
- Publication number
- CN109070507A CN109070507A CN201780025856.6A CN201780025856A CN109070507A CN 109070507 A CN109070507 A CN 109070507A CN 201780025856 A CN201780025856 A CN 201780025856A CN 109070507 A CN109070507 A CN 109070507A
- Authority
- CN
- China
- Prior art keywords
- layer
- textile
- plastisol
- preforming
- band
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
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- B29D29/06—Conveyor belts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/44—Compression means for making articles of indefinite length
- B29C43/48—Endless belts
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B29C66/12821—Stepped joint cross-sections comprising at least one overlap joint-segment comprising at least two overlap joint-segments
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
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- B29C66/4322—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms by joining a single sheet to itself
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
- B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
- B29C66/43—Joining a relatively small portion of the surface of said articles
- B29C66/432—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms
- B29C66/4324—Joining a relatively small portion of the surface of said articles for making tubular articles or closed loops, e.g. by joining several sheets ; for making hollow articles or hollow preforms for making closed loops, e.g. belts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/723—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined being multi-layered
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
- B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
- B29C66/729—Textile or other fibrous material made from plastics
- B29C66/7292—Textile or other fibrous material made from plastics coated
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B11/00—Connecting constructional elements or machine parts by sticking or pressing them together, e.g. cold pressure welding
- F16B11/006—Connecting constructional elements or machine parts by sticking or pressing them together, e.g. cold pressure welding by gluing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16G—BELTS, CABLES, OR ROPES, PREDOMINANTLY USED FOR DRIVING PURPOSES; CHAINS; FITTINGS PREDOMINANTLY USED THEREFOR
- F16G3/00—Belt fastenings, e.g. for conveyor belts
- F16G3/10—Joining belts by sewing, sticking, vulcanising, or the like; Constructional adaptations of the belt ends for this purpose
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29C43/32—Component parts, details or accessories; Auxiliary operations
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- B29C2043/483—Endless belts cooperating with a second endless belt, i.e. double band presses
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C43/28—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/52—Heating or cooling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/01—General aspects dealing with the joint area or with the area to be joined
- B29C66/05—Particular design of joint configurations
- B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
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- B29C66/128—Stepped joint cross-sections
- B29C66/1284—Stepped joint cross-sections comprising at least one butt joint-segment
-
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Abstract
方法包括:提供多个织物材料层,将增塑溶胶层(104)施加在形成多个织物材料层(102,106)的每个织物材料层之间,从而产生带骨架层,在至少5psi的压力下将这些织物材料层(102,106)与该一个或多个增塑溶胶层压在一起,以生产预成型的织物骨架层,同时将该预成型的织物骨架层加热至在约360℉至约450℉范围内的温度,持续至少6分钟的时间段,将热塑性弹性体聚氯乙烯合金组合物布置到该织物骨架层的上表面和下表面上,将该热塑性弹性体聚氯乙烯合金组合物压到该织物骨架层的上表面和下表面上,并且以阶梯式拼接构型来拼接该带的相反远端(112,114,116,118)。这些层可以没有邻近任何近端定位的织物层的邻接处布置的格子织物覆盖条。
Description
技术领域
本披露总体上涉及的领域是用热塑性聚合物制造的并且包括多层织物骨架层(fabric carcass)的传送带以及制造此类带的新颖方法。
背景技术
本部分提供背景信息以便于更好地理解本披露的各个方面。应该理解,本文件的本部分中的陈述将从这个角度阅读,并且不作为现有技术的承认。
在重型应用中使用的常规传送带典型地包含固化橡胶或聚氯乙烯(PVC)基材料作为顶层,固化橡胶或PVC基材料作为底层,以及布置在该顶层与该底层之间具有经线和纬线的单层织物增强层(骨架层)。该固化橡胶或聚氯乙烯基材料还可用于粘合织物增强骨架层的不同组分。例如,包含在骨架层中的单个层和增强元件可以被包封在聚合物弹性树脂例如聚氯乙烯基材料的基质中。单个层在连结在一起之前用液态弹性体形成聚合物树脂饱和,并且可以例如通过簇绒、缝合或针脚式接合***这些增强元件。在其中液态饱和物是聚氯乙烯增塑溶胶的情况下,通过施加热量,该树脂被胶化或以其他方式固化。
这些类型的传送带可以提供优异的性能特性和相对长的使用寿命。然而,这种构造受可使用的拼接技术类型的限制,并且通常要求机械拼接或指型拼接来作为成品生产带,这只能在复杂的操作中实现。此外,在一些实例中,具有基于通用PVC的顶层和/或底层的热塑性带可能存在与硬度、与传送材料或其他传送设备的摩擦系数、以及耐磨性不足有关的问题。
因此,持续需要利用改进的拼接技术以及由具有改进的特性的材料形成的顶层和底层来制造传送带,此类需要至少部分地由根据以下披露的实施例来满足。
发明内容
本部分提供了本披露的概述,并且不一定是其全部范围或其所有特征的全面披露。
在本披露的第一方面中,提供了一种制造环形带的方法,该方法包括:用增塑溶胶中的粘合剂浸渍织物材料以形成经涂覆的织物材料,在该经涂覆的织物材料的两个或更多个层之间施加增塑溶胶层,从而形成带骨架层,以及将该带骨架层连续进料到双带压机中,该双带压机在至少5psi的压力(或甚至在约14psi至约30psi的范围内的压力)下将经浸渍的织物材料与该一个或多个增塑溶胶层压在一起,以生产预成型的织物骨架层,同时加热该预成型的织物骨架层。然后,从该双带压机中连续地取出该织物骨架层,将热塑性弹性体聚氯乙烯合金组合物布置到该织物骨架层的上表面和下表面上,并且通过将该织物骨架层连续地进料到保持在至少340°F的温度和至少5psi的压力下的第二双带压机中,将该热塑性弹性体聚氯乙烯合金组合物压在该织物骨架层的上表面和下表面上。从该第二双带压机中连续地取出成品带,并且以阶梯式拼接构型将该带的相反远端拼接或以其他方式连接。在一些方面,在至少5psi的压力下将这些经浸渍的织物材料与该一个或多个增塑溶胶层压在一起,以生产预成型的织物骨架层,同时将该预成型的织物骨架层加热至在约360°F至约450°F的范围内的温度,持续至少6分钟的时间。对于一些实施例,由热塑性弹性体聚氯乙烯合金组合物形成的层没有邻近任何近端定位的织物层的邻接处布置的格子织物覆盖条。
在一些实施例中,该织物材料是聚酯织物或尼龙织物。该粘合剂可能包括约20重量百分比至约60重量百分比的甲苯二异氰酸酯和约40重量百分比至约80重量百分比的增塑剂,并且该粘合剂与该增塑溶胶的重量比可能在2:98至约10:90的范围内。在一些情况下,用增塑溶胶和粘合剂的混合物并且然后增塑溶胶顺序涂覆织物材料的内表面以形成经涂覆的织物材料。该热塑性弹性体聚氯乙烯合金组合物可以进一步包括至少一种填充剂,并且在一些方面,包括氯化的聚乙烯和任选的抗静电剂。
在本披露的另一个方面,方法包括:提供多个织物材料层,将增塑溶胶层施加在每个织物材料层(形成多个织物材料层)之间,由此产生带骨架层,将该带骨架层连续进料到双带压机中,该双带压机在至少5psi的压力下将这些织物材料层与该一个或多个增塑溶胶层压在一起,以生产预成型的织物骨架层,同时加热该预成型的织物骨架层,从该双带压机中连续取出该织物骨架层,将热塑性弹性体聚氯乙烯合金组合物布置到该织物骨架层的上表面和下表面上,通过将该织物骨架层连续进料到第二双带压机中来将该热塑性弹性体聚氯乙烯合金组合物压到该织物骨架层的上表面和下表面上,从该第二双带压机中连续取出成品带,以及(8)以阶梯式拼接构型来拼接该带的相反远端。在一些方面,可能在至少5psi的压力下将这些织物材料层与该一个或多个增塑溶胶层压在一起,以生产预成型的织物骨架层,同时将该预成型的织物骨架层加热至在约360°F至约450°F的范围内的温度,持续至少6分钟的时间段。甚至可以将该预成型的织物骨架层在该双带压机中保持在约380°F至约425°F的范围内的温度下,持续至少8分钟的时间段。由热塑性弹性体聚氯乙烯合金组合物形成的层也可以没有邻近任何近端定位的织物层的邻接处布置的格子织物覆盖条。
本披露的又其他实施例是以下方法,这些方法包括提供多个织物材料层,将增塑溶胶层施加在每个织物材料层(形成多个织物材料层)之间,由此产生带骨架层,在至少5psi的压力下将这些织物材料层与该一个或多个增塑溶胶层压在一起,以生产预成型的织物骨架层,同时将该预成型的织物骨架层加热至在约360°F至约450°F范围内的温度,持续至少6分钟的时间段,将热塑性弹性体聚氯乙烯合金组合物布置到该织物骨架层的上表面和下表面上,将该热塑性弹性体聚氯乙烯合金组合物压到该织物骨架层的上表面和下表面上,以及以阶梯式拼接构型来拼接该带的相反远端,其中由热塑性弹性体聚氯乙烯合金组合物形成的层没有邻近任何近端定位的织物层的邻接处布置的格子织物覆盖条。
附图说明
以下将参照附图描述本披露的某些实施例,其中相同的参考号表示相同的元件。然而,应当理解,附图示出了本文描述的各种实现方式并且不旨在限制本文所描述的各种技术的范围,并且:
图1以透视图示出了根据本披露的实施例的传送带的端部,在该端部层被剥离;
图2以透视图描绘了图1中所示的带的端部,其中层以阶梯式构型定向的轨迹;
图3示出了根据本披露的实施例的具有多层结构的传送带的横截面图,该多层结构具有阶梯式拼接配合构型;
图4以透视图示出了图3中所示的传送带的远端阶梯式端部的补充;
图5描绘了根据本披露的实施例的具有多层结构的传送带的横截面图,该多层结构具有遍及织物层的阶梯式拼接配合构型;
图6以透视图示出了图5中所示的传送带的远端阶梯式端部的补充;
图7示出了根据本披露的实施例的具有多层结构的传送带的横截面图,该多层结构具有遍及增塑溶胶层的阶梯式拼接配合构型;以及,
图8以透视图描绘了图7中所示的传送带的远端阶梯式端部的补充。
具体实施方式
以下变体说明本质上仅仅是说明性的,并且决不旨在限制本披露的范围、其应用或用途。说明和实例在此仅为了阐明本披露的不同实施例的目的呈现,并且不应被解释为对本披露的范围和适用性的限制。虽然本披露的组合物在此被描述为包含某些材料,但是应当理解,该组合物可以任选地包含两种或更多种化学上不同的材料。此外,该组合物还可以包含除了已经列举的组分之外的一些组分。在本披露的发明内容和该具体实施方式中,每个数值应该如被术语“约”修饰的读取一次(除非已经明确地被如此修饰),并且然后如没有被如此修饰的再次读取,除非在上下文中另外指明。此外,在本披露的发明内容和该具体实施方式中,应当理解,列出或描述为有用的、合适的等的浓度或量范围或尺寸意图是在该范围内的全部浓度或量或尺寸(包括端点)被认为已经进行陈述。例如,“从1至10的范围”将被读为指示沿着在约1与约10之间的连续体的每一个可能的数字。因此,即使在该范围内的特定数据点,或者甚至没有在该范围内的数据点被明确地指明或仅仅是指几个特定点,应当理解,诸位发明人领会且理解,在该范围内的任何和所有数据点被认为已经被指定,并且诸位发明人拥有整个范围和在该范围内的所有点。
除非明确相反地说明,否则“或”是指包括性的或并且不是排他性的或。例如,通过以下任意一种情况都可以满足条件A或B:A为真(或存在)且B为假(或不存在),A为假(或不存在)且B为真(或存在),A与B均为真(或存在)。
此外,使用“一个/一种(a/an)”用来描述在此的实施例的元素和组分。这样做仅仅为了方便起见,并且给出根据本披露的概念的一般含义。该说明应被阅读为包括一个/一种或至少一个/一种,并且除非另有说明,单数还包括复数。
在此使用的术语和词组是为了描述的目的并且不应被解释为在范围上的限制。语言诸如“包括”、“包含”、“具有”、“含有”或“涉及”及其变体旨在是广泛的并且包括其后列出的主题、等效物、和未被列出的附加主题。
此外,如在此所使用的,对“一个(one)实施例”或“一个(an)实施例”的任何提及意味着与该实施例有关所描述的具体元素、特征、结构或特性包括在至少一个实施例中。在说明书中的不同地方中短语“在一个实施例中”的出现不一定是指同一个实施例。
根据本披露的方法制备的传送带典型地包括弹性主体,该弹性主体具有负荷承载表面和平行皮带轮接合层,以及布置在该带的弹性主体内的含有织物增强件的骨架层。该织物增强骨架层典型地包括多个织物层,其中中间层布置在其上。在一些实施例中,传送带被形成为连续带,并且末端以使得能够在多个层之间进行阶梯式拼接的这样的方式切割和成形,如在下文中进一步详细描述的。在一些方面,此阶梯式拼接确保了拼接缝中的所有层不同时接近传动皮带轮。这些特征虽然不是必需的,但在一些应用中可以改善拼接接头。
适用于传送带应用的各种天然或合成的弹性体材料的任一种可能用来形成该负荷承载层、底层、皮带轮接合层、以及一个或多个中间层,包括但不限于如在美国专利号8,910,780 B2(将其通过引用结合在此)中所披露的带中使用的描述的那些材料。示例性材料的非限制性清单包括:氯磺酰基聚乙烯、天然橡胶、氯丁二烯、丁腈橡胶、丁二烯橡胶、异戊二烯、苯乙烯丁二烯、改性的聚硅氧烷、聚酯氨基甲酸乙酯、聚醚氨基甲酸乙酯、聚氯乙烯、碳氟聚合物、聚烯烃,如聚乙烯或聚丙烯等。当用于形成这些中间层时,弹性体材料可能是呈增塑溶胶的形式,如可以简单地通过加热转化成固体塑料的液态物质,并且该液态物质由分散在非挥发性液体中的合成树脂的颗粒组成。在一些实施例中,该弹性体材料包含天然橡胶。在一些其他实施例中,该合成弹性体材料是基于热塑性弹性体聚氯乙烯合金(TPE/PVC合金)的那些。当使用时,该热塑性弹性体聚氯乙烯合金覆盖材料的特性将与橡胶的特性相似或类似,并且具有在约60肖氏A至约70肖氏A之间的范围内的硬度值、低于200mm3的DIN磨损值以及高的摩擦系数。此外,这种材料可以包括弹性体和更永久的增塑剂二者以确保最佳的柔性保留。
由于PVC具有高的极性和与各种其他高性能塑料的高的相容性,它们可以被混合以形成聚合物合金。使用聚合物合金化技术,可以克服纯硬质PVC组分的缺点。通常,为了改进在本披露的一些方面中有用的PVC材料的特性,将具有橡胶状特性的添加剂,如丙烯腈-丁二烯-苯乙烯(ABS)、甲基丙烯酸甲酯-丁二烯-苯乙烯(MBS)、丙烯酸橡胶、氯化的聚乙烯、乙烯-乙酸乙烯酯(EVA)的聚合物等,与PVC混合。通过在混配工序中将约5至约25重量份的这些添加剂共混到100重量份的PVC中,可以获得根据本披露的一些实施例使用的足够特性。在一些方面,呈微粒形式的添加剂被分散在PVC的微观结构中。当这些PVC层接收冲击或其他典型的力时,分子结构中的这些微粒吸收冲击能并且防止对这些PVC层的损害。
用于形成根据本披露的传送带的弹性体材料还可以包括用于增强阻燃性、耐磨性和抗结块性、耐滚动性、耐老化性(例如,耐臭氧和UV性)等的添加剂。还可以使用固化助剂、交联剂、油、促进剂、或其他成形助剂。
类似地,中心增强层可以由各种材料中的任何一种(织造或非织造)以任何期望的重量和定向形成,并且包括通过适当的弹性体或粘合剂层分开的多个单个层。此类材料可以包括各种合成和人造纤维,包括聚酯、尼龙、芳族聚酰胺(例如Kevlar)、玻璃、聚丙烯、纤维素、羊毛或其他。这些纤维可能是多丝、单丝或短纤维。在一个实施例中,该中心增强层包括多层的聚酯和/或尼龙。
在一些方面,这些多层是由用在增塑溶胶中的粘合剂连续浸渍以形成经涂覆的织物材料的织物形成的。在一些情况下,使用的织物可以由棉、聚酯、尼龙或其共混物构成。例如,该聚酯可以是聚对苯二甲酸乙二醇酯或聚萘二甲酸乙二醇酯。在一些情况下,该聚酯可以是含有衍生自对苯二甲酸和间苯二甲酸或其二甲酯的重复单元的共聚酯。在此类情况下,共聚酯一般将含有至少约95重量%的对苯二甲酸和达到约5重量%的间苯二甲酸。更典型地,该共聚酯将含有至少约97重量百分比的对苯二甲酸和高达约3重量百分比的间苯二甲酸。该聚酯织物可以任选地由聚酯短纤纱制成,以改善粘附特性。可以与本披露结合使用的尼龙织物可以由几乎任何类型的尼龙构成,例如尼龙-6,6、尼龙-6,12、尼龙-6,10、尼龙-6,9、尼龙-6、尼龙-11或尼龙-12。出于商业原因,尼龙一般将是尼龙-6,6或尼龙-6。在任何情况下,当使用时,该织物材料将典型地是织造织物,尽管非织造织物也可能是有用的。
经浸渍的织物的表面是将与中间层(无粘合剂)接触的表面,并且此类中间层也可以与构成织物骨架层的其他织物层接触,最终用作传送带的骨架层。在一些方面,该浸渍步骤是以连续过程通过使该织物在低张力下穿过浸渍区域,如浸浴或涂覆轮来进行的,优选小于6磅每英寸宽度、更优选在1至5磅每英寸宽度(0.179至0.893kg/cm宽度)的范围内。该粘合剂与该增塑溶胶的重量比可能在2:98至10:90的范围内,或甚至在4:96至8:92的范围内。在一些情况下,该粘合剂与该增塑溶胶的重量比可能在5:95至7:93的范围内。然而,粘合剂与增塑溶胶的重量比的任何适合的值是在本披露的范围内。
在根据本披露的一些实施例中使用的增塑溶胶是基于PVC的分散体,而在一些其他实施例中是热塑性弹性体聚氯乙烯合金。使用的粘合剂典型地含有二异氰酸酯基团,其可以改善织物与PVC之间的粘附特性。如在美国专利号7,776,768B2(其通过引用结合在此)中所披露的,优选的是使用异氰尿酸酯作为粘合促进剂,这些异氰尿酸酯含有异氰酸酯基团并且可以通过低聚、尤其是三聚由二异氰酸酯来制备。最适合用于此目的的二异氰酸酯是容易商购获得的同分异构的二异氰酸甲苯(TDI)的混合物,主要由2,4-二异氰酸甲苯(2,4-TDI)和2,6-二异氰酸甲苯(2,6-TDI)构成。这些可以容易地几乎完全反应以得到含有异氰酸酯基团的异氰尿酸酯。几乎完全反应是必要的,因为操作员安全和产品安全要求在粘合促进剂制备中的二异氰酸酯的残留含量保持按重量计低于1.0%。二异氰酸二苯基甲烷(MDI)同样容易获得但是较不合适,并且比TDI更难三聚,并且因此可以导致不希望地高的二异氰酸酯的残留含量。此外,含有基于MDI的异氰酸酯基团的异氰尿酸酯显示出差的可溶性,并且具有结晶的趋势。
当含有异氰酸酯基团的异氰尿酸酯以在增塑剂中的溶液的形式使用时,它们特别容易作为粘合促进剂处理。在实际方法中,含有异氰酸酯基团并且衍生自TDI的异氰尿酸酯同样在用作溶剂的增塑剂中制备。DE 24 19 016 A1(GB 145 570 A1)通过举例描述了这些包含增塑剂的粘合促进剂和粘合促进剂制剂,以及其制备和其用途。
在接下来的步骤中,将无粘合剂的至少一个增塑溶胶层施加在两个经浸渍的织物层之间。根据经浸渍的织物层的数量重复该过程。该增塑溶胶可以是与用于浸渍织物的增塑溶胶相同或不同的。一旦施加该增塑溶胶层,它可能通过加热至在约100°F(37.8℃)与约200°F(93.3℃)之间、更优选在150°F(65.5℃)与约180°F(82.2℃)之间的温度来预凝胶化。该过程以织物层上的最小张力完成,优选小于约6磅每英寸的宽度(1.071kg/cm的宽度)、并且更优选在约1至约5磅每英寸的宽度(0.179至0.893kg/cm的宽度)的张力下完成。该步骤的结果是预凝胶化的织物骨架层。
然后,可以将该预凝胶化的织物骨架层连续进料到双带压机中,其中在至少约5psi(3.5×104帕斯卡)的压力下将其压在一起。该带压机的带将典型地具有由聚四氟乙烯(PTFE)浸渍的纤维玻璃或不锈钢薄层构成的表面。该带压机将典型地施加约5psi至约35psi(3.5×104帕斯卡至2.4×105帕斯卡)、更典型地约10psi至约30psi的压力,将优选地施加约12psi至约25psi(8.3×104帕斯卡至1.7×105帕斯卡)、并且将最优选地约15psi至约20psi(1.0×105帕斯卡至1.4×105帕斯卡)的压力。
可以将该织物骨架层在双带压机中保持在约360°F(182℃)至约450°F(232℃)的范围内的温度下,持续至少约6分钟的时间段。该温度将优选地保持在约375°F(191℃)至约425°F(218℃)的范围内,并且将最优选地保持在约390°F(199℃)至约410°F(210℃)的范围内。该织物骨架层在双带压机中可能典型地具有在约8分钟至约14分钟范围内的停留时间,并且在双带压机中将最优选具有在约9分钟至约12分钟范围内的停留时间。
在双带压机中保持所希望的停留时间后,可以将该织物骨架层作为成品织物骨架层从该压机中连续移除,该成品织物骨架层适合用作传送带的骨架层。在一个实施例中,随着成品织物骨架层从双带压机中取出,用其连续制造此种传送带。在此种过程中,将弹性体材料连续布置到该织物骨架层的上表面和下表面上以形成负荷承载层和皮带轮接合覆盖层。该弹性体材料以颗粒形式提供,这些颗粒典型地具有在约0.25mm与约1mm之间的尺寸分布,其中平均尺寸为约0.5mm。然后,通过将织物增强件连续地进料到保持在至少约340°F(171℃)的温度下的第二双带压机中,将该弹性体材料压在该织物增强件的上表面和下表面上。该弹性体材料可任选地包括填充剂,如碳酸钙,着色剂,如碳黑或二氧化钛,阻燃剂,抗微生物剂,抗静电剂和/或抗真菌剂。在将该弹性体材料压到织物骨架层的上表面和下表面上之后,可以将带切割成希望的尺寸并且在远端形成拼接台阶,如在以下进一步详细描述的。
使用利用根据本披露的方法制造的织物增强件制备的传送带典型地包括弹性主体,该弹性主体具有负荷承载表面和平行的皮带轮接合表面,其中将该一种或多种织物增强件布置在该带的弹性主体内。此种传送带100的一端在图1中描绘,其中该织物增强件由第一织物层102、增塑溶胶层104以及第二织物层106构成。该织物增强件位于带100的皮带轮覆盖层108与负荷承载层110之间。虽然描绘了两个织物层102和106,但是在根据本披露制备的带中可以使用任何适合数量的织物层,如二个、三个、四个、五个、六个等。如图1中描绘的,负荷承载层110的远端112是在第一纵向位置形成的,该位置相对于第一织物层102的相应端凹进以提供阶梯式构型。如图2中更详细所示,负荷承载层110的末端112相对于第一织物层102的相应末端114凹进,增塑溶胶层104的末端116相对于末端114凹进,第二织物层106的末端118相对于末端116凹进,并且皮带轮覆盖层108的末端120相对于末端118凹进。带100的相反远端包括相反定向的末端,以提供用于形成远端的阶梯式拼接的台阶的配合构型,其在以下图3和图4中所示的实施例中进一步详细地示出。
现在参照图3,示出了传送带300的横截面图,其包括远端302和304,各自具有层306至322的阶梯式构型,它们在该带300的区域324处被阶梯式拼接。传送带300包括负荷承载层306和皮带轮覆盖层308,其间布置有织物骨架层。该织物骨架层在结构上包括:第一织物层310、第二织物层312、第三织物层314以及第四织物层316,其中增塑溶胶层318、320以及322布置在如所描绘的织物层之间。如所描绘的,负荷承载层、皮带轮覆盖层、织物和增塑溶胶层的末端中的每一个在带300的远端区域302和304处顺续地凹进或前进(advance),以便为配合末端提供邻接的层边缘,以在区域324内提供阶梯式拼接而在配合末端之间无显著的间隙,间隙可能导致带的分离。通过图4中呈现的透视图进一步更详细示出此类顺序凹进或前进的层末端,其中描绘了在阶梯式拼接之前的远端区域302和304。
参照图5,示出了传送带500的横截面图,其包括远端502和504,各自具有层506至522的阶梯式构型,它们在该带的区域524处被阶梯式拼接。然而,与在图3中所描绘的实施例相比,每个台阶的配合面都是织物。传送带500包括:负荷承载层506、皮带轮覆盖层508以及布置在其间的织物骨架层,该织物骨架层包括第一织物层510、第二织物层512、第三织物层514以及第四织物层516,以及如所描绘的布置在织物层之间的增塑溶胶层518、520和522。负荷承载层、皮带轮覆盖层、织物和增塑溶胶层的末端在远端区域502和504部分或者全部顺序凹进或前进,以提供具有邻接层边缘的配合末端,从而允许在区域524内进行阶梯式拼接而在配合末端之间无显著的间隙,间隙可能导致该带的分离。图6通过透视图更详细地示出了带500的末端远端区域502和504。如图6中所描绘的,由织物形成台阶面526、528、530、532、534、536、538以及540,其在配合时提供了在配合末端无间隙的拼接织物层。台阶面526与面534配对、面528与面536配对、面530与面538配对、并且面532与面540配对,以形成阶梯式拼接。
在本披露的一些其他实施例中,在增塑溶胶层中可能形成台阶面,如在图7和图8中所描绘的。现在参照图7,传送带700包括远端702和704,各自具有如所描绘的层706至722的阶梯式构型,它们在区域724被阶梯式拼接。然而,与以上所描绘的实施例相比,每个台阶的配合面都是增塑溶胶。负荷承载层706、皮带轮覆盖层708、织物层710、712、714、716,以及增塑溶胶层718、720、722的末端在远端区域702和704部分或者全部顺序凹进或前进,以提供具有邻接层边缘的配合末端,从而允许在区域724内进行阶梯式拼接,而在配合末端之间没有间隙。图8以透视图示出了带700的末端远端区域702和704,其中台阶面726、728、730、732、734以及736由增塑溶胶形成,其在拼接时提供拼接的增塑溶胶层而在配合末端中没有间隙。如所描绘的,台阶面726与面732配对、面728与面734配对并且面730与面736配对,以形成阶梯式拼接。
虽然上述实施例示出了特定层的台阶面或在特定层内的台阶面,但是在本披露的范围和精神内的是在不同层的任一个的界面内或界面处形成的台阶面包括在传送带的结构中。例如,一个台阶面可能位于织物层的外表面,而下一个台阶面可能在织物层或增塑溶胶层内形成,而在一些其他情况下,台阶面可能在增塑溶胶层的外表面形成,而另一个台阶面在织物层或增塑溶胶层内形成。这些台阶面的任何适合的位置是在本披露的范围内。此外,分开的相邻邻接末端之间的距离是使得能够实际构造带、但是避免多个或所有邻接末端同时在皮带轮上遇到动力转动的任何适合的距离。
在本披露的一些方面,结合基于热塑性弹性体聚氯乙烯合金的皮带轮覆盖层、负荷承载层、增塑溶胶层或其组合,使用所述的阶梯式拼接技术提供了比机械拼接更强的拼接,具有比指型拼接较不复杂的远端接合。此外,由于用更薄的层替代厚的织物层与具有较低模量的热塑性弹性体聚氯乙烯合金材料的使用耦合在一起,该多层骨架层产生更好的柔性。在又其他方面,根据本披露制备的传送带实施例消除了对最外和/或最内的织物网层的需要,所述织物网层覆盖有格子织物的覆盖条朝向最外和/或最内的覆盖片材,如在美国专利申请公开号20120015572A1(将其通过引用结合在此)中所披露的带中使用的。换言之,这些皮带轮覆盖层和/或负荷承载层是均匀连续弹性体层,其没有邻近任何近端定位的织物层的邻接处布置的格子织物覆盖条。
为了说明和描述的目的,已经提供了对实施例的前述描述。提供了示例性实施例,使得本披露将是充分彻底的,并且将范围传达给本领域技术人员。阐述许多具体细节,例如特定组分、装置和方法的实例,以提供对本披露的实施例的彻底理解,但并不旨在是穷尽的或限制本披露。应当理解,在本披露的范围内的是具体实施例的单独的元素或特征通常不限于该具体实施例,而是在适用的情况下是可互换的并且可以在所选择的实施例(即使不是明确示出或描述的)中使用。其也可以以许多方式变化。此类变化不被视为偏离本披露,并且所有此类修改旨在被包括在本披露的范围内。
而且,在一些示例性实施例中,未详细描述众所周知的过程、众所周知的装置结构以及众所周知的技术。此外,对本领域技术人员来说将显而易见的是,在仪器的设计、制造和操作以实现本披露所描述的,例如,可能存在仪器设计、结构、状态、部件的腐蚀、部件之间的间隙的变化。
尽管术语第一、第二、第三等可以在此用于描述不同的元件、部件、区域、层和/或部分,这些元件、部件、区域、层和/或部分不应受这些术语的限制。这些术语可以仅用于将一种元件、部件、区域、层或部分与另一种区域、层或部分区分开。术语如“第一”、“第二”和其他数字术语当在此使用时不意味着次序或顺序,除非上下文清楚地指出。因此,在不背离示例性实施例的传授内容下,以下所讨论的第一元件、部件、区域、层或部分可以被称为第二元件、部件、区域、层或部分。
为了便于描述,空间相对术语,如“内部”、“相邻”、“外部”、“下面”、“下方”、“下部”、“上方”、“上部”等,可以在此处用于描述一种元件或特征与另外的一种或多种元件或特征的关系,如图所示。除了图中所描述的定向外,空间相对术语可以旨在包括使用或操作中的装置的不同定向。例如,如果将图中的装置翻转,则被描述为在其他元件或特征“下方”或“下面”的元件将被定向为在该其他元件或特征的“上方”。因此,示例性术语“下方”可以包括上方和下方的定向二者。该装置可以以其他方式定向(旋转90度或其他定向),并且在此使用的空间相对描述语可以被相应地解释。
虽然上面已经详细描述了本披露的几个实施例,但是本领域普通技术人员将容易地理解,在不实质背离本披露的传授内容的情况下,许多修改是可能的。因此,此类修改旨在被包括在如权利要求书中限定的本披露的范围内。
Claims (10)
1.一种制造带的方法,该方法包括:
(a)将织物材料用增塑溶胶中的粘合剂浸渍以形成经涂覆的织物材料;
(b)将增塑溶胶层施加在经涂覆的织物的两个或更多个层之间,由此产生带骨架层;
其特征在于:
(c)将该带骨架层连续进料到双带压机中,该双带压机在至少5psi的压力下将这些经浸渍的织物材料与该一个或多个增塑溶胶层压在一起,以生产预成型的织物骨架层,同时加热该预成型的织物骨架层;
(d)从该双带压机中连续地取出该织物骨架层;
(e)将热塑性弹性体聚氯乙烯合金组合物布置到该织物骨架层的上表面和下表面上;
(f)通过将该织物骨架层连续地进料到第二双带压机中来将该热塑性弹性体聚氯乙烯合金组合物压到该织物骨架层的上表面和下表面上,将该第二双带压机保持在至少171℃的温度和至少34.5kPa的压力下;
(g)从该第二双带压机中连续地取出成品带;以及,
(h)以阶梯式拼接构型来拼接该带的相反远端。
2.如权利要求1所述的方法,其中,该织物材料是聚酯织物。
3.如权利要求1所述的方法,其中,该织物材料是尼龙织物。
4.根据前述权利要求中任一项所述的方法,其中,该粘合剂包含约20重量百分比至约60重量百分比的甲苯二异氰酸酯和约40重量百分比至约80重量百分比的增塑剂。
5.根据前述权利要求中任一项所述的方法,其中,用增塑溶胶和粘合剂的混合物并且然后增塑溶胶顺序地涂覆该织物材料的表面以形成经涂覆的织物材料。
6.根据前述权利要求中任一项所述的方法,其中,该粘合剂与该增塑溶胶的重量比是在约2:98至约10:90的范围内。
7.根据前述权利要求中任一项所述的方法,其中,在14psi至30psi的范围内的压力下将该双带压机中的经涂覆的织物材料压在一起以生产预成型的织物骨架层。
8.如权利要求7所述的方法,其中,在该双带压机中将该预成型的织物骨架层保持在约193℃至约218℃的范围内的温度下持续至少8分钟的时间段。
9.如权利要求1所述的方法,其中,在至少34.5kPa的压力下将这些经浸渍的织物材料与该一个或多个增塑溶胶层压在一起,以生产预成型的织物骨架层,同时将该预成型的织物骨架层加热至在约182℃至约232℃范围内的温度,持续至少6分钟的时间段。
10.根据前述权利要求中任一项所述的方法,其中,由该热塑性弹性体聚氯乙烯合金组合物形成的这些层没有邻近任何近端定位的织物层的邻接处布置的格子织物覆盖条。
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