Patent Publication Number: US-2022212874-A1

Title: Belt module and conveyor belt with sturdy edge

Description:
BACKGROUND 
     The invention relates generally to power-driven conveyors. In particular the invention relates to conveyor belt modules joined at hinges to form modular conveyor belts. 
     Modular plastic conveyor belts are used to convey products. The belts are constructed of rows of plastic belt modules joined by hinge rods at hinge joints. For repair and often for cleaning, a belt has to be partly disassembled for a broken module to be replaced or for the belt to be removed from the conveyor frame for remote cleaning. The first stage in disassembling a modular plastic conveyor belt is the removal of a hinge rod by plant maintenance personnel. When in a hurry or without a proper tool at hand, maintenance personnel may snip or otherwise break off an edge of belt to expose the end of a hinge rod for a better purchase to pull it out of its hinge joint. Once the hinge rod is extracted, the belt can be removed from the conveyor, or broken modules can be replaced. But the broken belt edge loses its effectiveness as a hinge-rod retainer and becomes a potential snag point. 
     SUMMARY 
     One version of a conveyor belt module embodying features of the invention comprises a deck extending in length from a first end to a second end, laterally in width from a first side to a second side, and in thickness from a top side to a bottom side. First hinge elements are spaced apart laterally across the width of the deck along the first end, and second hinge elements are spaced apart laterally across the width of the deck along the second end. A rib protrudes from and extends laterally along the bottom side of the deck. The rib divides the bottom side of the deck into a first region forming a first channel between the rib and the first hinge elements and a second region forming a second channel between the rib and the second hinge elements. A module edge portion extends laterally outward from the first side of the deck to an outer edge. The module edge portion includes a top surface forming a continuation of the top side of the deck from the first side out to the outer edge and a bottom surface extending laterally inward from the outer edge short of the first side of the deck. The bottom surface forms with the top surface a thickened outer edge region thicker than the deck. 
     One version of a conveyor belt embodying features of the invention comprises a series of rows of one or more conveyor belt modules extending laterally in width from a first belt edge to a second belt edge and hingedly connected end to end at hinge joints between consecutive rows. Each of the rows includes a deck that extends in length from a first end to a second end, laterally across the row in width from a first side to a second side, and in thickness from a top side to a bottom side. First hinge elements are spaced apart laterally across the width of the deck along the first end, and second hinge elements are spaced apart laterally across the width of the deck along the second end. A rib protrudes from and extends laterally along the bottom side of the deck. The rib divides the bottom side of the deck into a first region forming a first channel between the rib and the first hinge elements and a second region forming a second channel between the rib and the second hinge elements. A first module edge portion extends laterally outward from the first side of the deck to an outer edge defining the first belt edge, and a second module edge portion extends laterally outward from the second side of the deck to an outer edge defining the second belt edge. Each of the first and second module edge portions includes a top surface forming a continuation of the top side of the deck from the first side out to the outer edge and a bottom surface extending laterally inward from the outer edge short of the deck. The bottom surface forms with the top surface a thickened outer edge region. 
     One version of a conveyor embodying features of the invention comprises a conveyor belt and a reversing element. The conveyor belt is constructed of a series of rows of one or more conveyor belt modules extending laterally in width from a first belt edge to a second belt edge and hingedly connected end to end at hinge joints between consecutive rows. Each of the rows includes a deck extending in length from a first end to a second end, laterally across the row in width from a first side to a second side, and in thickness from a top side to a bottom side. First hinge elements are spaced apart laterally across the width of the deck along the first end, and second hinge elements are spaced apart laterally across the width of the deck along the second end. A rib protrudes from and extends laterally along the bottom side of the deck. The rib divides the bottom side of the deck into a first region forming a first channel between the rib and the first hinge elements and a second region forming a second channel between the rib and the second hinge elements. A first module edge portion extends laterally outward from the first side of the deck to an outer edge defining the first belt edge, and a second module edge portion extends laterally outward from the second side of the deck to an outer edge defining the second belt edge. Each of the first and second module edge portions includes a top surface forming a continuation of the top side of the deck from the first side out to the outer edge and a bottom surface extending laterally inward from the outer edge short of the deck. The bottom surface forms with the top surface a thickened outer edge region thicker than the deck. The reversing element has a cylindrical periphery with a plurality of lateral grooves sized to receive the ribs and opening up at each end of the lateral grooves to edge recesses sized to receive the bottom surfaces of the thickened outer edge regions. The bottom surfaces are confined in the edge recesses to limit lateral wander of the conveyor belt along the reversing element. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1A-1C  are top isometric, bottom isometric, and bottom plan views of one version of two joined conveyor belt modules embodying features of the invention. 
         FIGS. 2A-2C  are top isometric, bottom isometric, and bottom plan views of another version of two joined conveyor belt modules embodying features of the invention. 
         FIG. 3  is a bottom isometric view of the belt modules of  FIG. 2  showing hinge rod removal by screwdriver. 
         FIG. 4  is a side elevation view of a conveyor belt constructed of modules as in  FIG. 1A  or  FIG. 2A . 
         FIGS. 5A and 5B  are top and bottom isometric views of another version of a belt module embodying features of the invention and usable in a belt as in  FIG. 4 . 
         FIGS. 6A and 6B  are top and bottom isometric views of yet another version of a belt module embodying features of the invention and usable in a belt as in  FIG. 4 . 
         FIG. 7  is an isometric view of a full-width reversing element engaged with a conveyor belt constructed of belt modules as in  FIG. 2A . 
     
    
    
     DETAILED DESCRIPTION 
     One version of conveyor belt modules having sturdy, thickened edges is shown in  FIGS. 1A-1C . The modules  10  each have a deck  12  that extends in length from a first end  14  to a second end  15  in a direction of belt travel  16 , laterally in width from a first side  18  to a second side  19 , and in thickness from a top side  20  to a bottom side  21 . First hinge elements  22  are spaced apart laterally across the width of the deck  12  along the first end  14 . Second hinge elements  23  are spaced apart laterally across the width of the deck  12  along the second end  15 . Gaps  24  between consecutive hinge elements  22 ,  23  are sized to receive the hinge elements of an adjacent module in an interleaved arrangement in which rod holes  26  extending laterally through the interleaved hinge elements are aligned to form a lateral passageway. The interleaved hinge elements  22 ,  23  of adjacent modules  10 , together with a hinge rod  28  received in the passageway, form a hinge joint  30  connecting the adjacent modules. 
     One of the first hinge elements  22 —the one closest to the first side  18  of the deck  12 —is a laterally wider first hinge element  22 A serving as an indexing hinge element. A corresponding wide space  24 A at the first side  18  and the second end  15  is sized to receive the wide first hinge element  22 A of an adjacent module  10 . Because the wide hinge element  22 A is too wide to fit in the other spaces  24  along the second end  15 , the modules  10  can&#39;t be mistakenly misaligned during assembly: there is only one way to join them together. The wide hinge element  22 A and the wide space  24 A could alternatively be formed at other lateral positions along the groups of hinge elements  22 ,  23  to prevent the modules from being misaligned during assembly. 
     A rib  32  protruding from the bottom side  21  of the deck  12  extends laterally between the first and second sides  18 ,  19 . The rib  32 , which can serve as a drive bar for a drive sprocket or as an impact bar, divides the bottom side  21  of the deck  12  into a first region forming a first channel  34  between itself and the first hinge elements  22  and a second region forming a second channel  35  between itself and the second hinge elements  23 . 
     A module edge portion  36  extends laterally outward from the first side  18  of the deck  12  to an outer edge  38 . The edge portion  36  has a top surface  40  that forms a continuation of the top side  20  of the deck  12  out to the outer edge  38 . A bottom surface  41  of the edge portion  36  extends laterally inward of the outer edge  38  short of the first side  18  of the deck  12 . The bottom surface  41  forms a thickened outer edge region  42  with the top surface  40  and can be made wide enough to serve as a wear pad that slides along a carryway wearstrip. The thickened outer edge region  42  extends through the thickness of the module  10  on the module edge portion  36 . A rib continuation  44  on the edge portion  36  extends from the bottom-side rib  32  at the first side  18  of the deck  12  to the bottom surface  41  to form extensions of the first and second channels  34 ,  35  onto the module edge portion out to the thickened outer edge region  42 . The bottom surface  41  of the edge portion  36 , the rib continuation  44 , and the rib  32  extend to the same level  46  so as to be coplanar in this version. But they could extend to different levels in other versions. 
     The rib continuation  44  curves away from collinear alignment with the rib  32  to meet the bottom surface  41  at a first edge end  48  of the edge portion  36 . The first edge end  48  is aligned with the first end  14  of the deck  12 . An opposite second edge end  49  is outwardly offset in the length direction from the second end  15  of the deck  12 . An edge hinge element  50  at the second edge end  49  has a rod hole  52  aligned with the rod holes  26  of the second hinge elements  23  along the second end  15  of the deck  12 . The end of the hinge rod  28  normally resides between the edge hinge element  50  and the thickened outer edge region  42 . 
     A web  54  extends from the thickened outer edge region  42  inward to the edge hinge element  50 . The curved web  54  is continuous with the top surface  40  and extends around the circumference of the edge hinge element  50  to form a nose extending laterally along the second edge end  49  of the module edge portion  36 . The web  54  extends circumferentially far enough to provide a guard preventing a finger from being pinched at the hinge joint  30 . An inner wall  55  aligned with and facing the second hinge elements  22  and the edge hinge element  50  forms a stop for the hinge rod  28 . 
     The end of the extension of the second channel  35  opens into a broader terminal space, a lacuna  56 , bounded by the rib continuation  44 , the thickened outer region  42 , and the web  54 . Cleaning fluid or water sprayed onto the bottom side of a conveyor belt in the belt return advances along the second channel  35  and into the lacuna  56 , which exposes the edge hinge element  50 , the inner side of the web  54 , and the end of the hinge rod  28  to the cleaning fluid as indicated by the arrow  58 . Cleaning fluid or water is guided by the first channel  34  to the first edge end  48  to clean between the edge portions  36  of adjacent modules  12 , as indicated by the arrow  59 . 
     The flat bottom surface  41  extends inward of the outer edge  38  to a ramp  57  that slopes further inward to the bed of the lacuna  56 . The curved ramp  57 , which forms an inner wall bounding the lacuna  54 , prevents a pliers from getting a good purchase on the module edge portion  36  and snapping it off. 
     Another version of conveyor belt modules is shown in  FIGS. 2A-2C . The modules  60  are similar to those in  FIGS. 1A-1C , except that module edge portions  62  have a linear rib continuation  64  that is collinear with the rib  32  on the bottom side  21  of the deck  12 . Because the rib continuation  64  does not curve away from collinear alignment with the rib  32 , a lacuna  66  bounded by the rib continuation  64 , a thickened outer edge portion  68 , and the inner side of the web  54  is smaller than the lacuna shown in  FIGS. 1B and 1C , but broader than the extended second channel  35 . The extended second channel  35  opens into the lacuna  66  to guide cleaning fluid or water to the back of the web  54  and the edge hinge element  50  as indicated by the arrow  70 . The collinear rib continuation  64  provides a longer exposed area  72  at the first edge end  48  of the module edge portion  62 . 
     As shown in  FIG. 3 , the hinge rod  28  can be easily removed from the hinge joint  30  with a removal tool, such as a screwdriver  74 . If a screwdriver is used the flat of the screwdriver  74  is inserted between the end of the hinge rod and the bed  76  of the lacuna  66 . Then the screwdriver  74  is rotated about 90°, as indicated by the arrow  78 , to lift the end of the hinge rod  28  away from the bed  76  and up an inner wall  80  of the thickened outer edge portion  68 . The lifted end of the hinge rod  28  can then be grasped by a pliers or the fingers and pulled from the hinge joint  30  to disconnect the belt rows. 
     The rows are reconnected by first interleaving their first and second hinge elements  22 ,  23  into alignment. Then the end portion of the hinge rod  28  is bent and slid along a depression  82  in the outer edge portion  68  and into the rod hole in the edge hinge element  50 . The hinge rod  28  is then pushed through the lateral passageway formed by the interleaved hinge elements  22 ,  23  to rejoin the two adjacent belt rows. 
     A modular conveyor belt  84  constructed of rows  86  of belt modules  10  ( FIGS. 1A-1C ) or belt modules  60  ( FIGS. 2A-2C ) is shown in  FIG. 4 . The rows  86  include one or more belt modules, including edge modules  10  (or  60 ) at the opposite outer edges  88  of the belt  84  and interior belt modules like the edge modules  10  (or  60 ), but without the module edge portion  38  (or  68 ). Such a modular belt with multiple modules per row  86  is typically arranged with the modules in a bricklay pattern to avoid continuous seams along the length of the belt. And the deck in each row of multiple modules is still considered to be continuous despite the narrow seams between abutting, laterally adjacent modules. Belt modules with module edge portions  38  (or  68 ) at both sides can be used to construct seamless belt rows consisting of only one belt module per row. In those belt modules the module edge portions  38  (or  68 ) are arranged with their edge hinge elements at opposite ends of the module for reversibility. The conveyor belt  84  is trained around drive and idle sprockets  90 ,  91  and supported along an upper carryway by wear strips  92  on which at least the bottom surfaces of the outer edge portions of the belt edge modules slide. The belt  84  returns from the drive sprocket  90  to the idle sprocket  91  in a lower return. 
     Another version of a belt edge module usable in a conveyor belt as in  FIG. 4  is shown in  FIGS. 5A and 5B . The belt module  94  differs from the modules  10 ,  60  of  FIGS. 1A-1C  and  FIGS. 2A-2C  in that it does not have a lacuna into which one of its channels  98 ,  99  opens and it does not have an enlarged indexing hinge element. The channels terminate at a thickened outer edge region  96  forming an outer edge portion of the module. A slot  102  extends at an angle from the module&#39;s bottom surface  104  along an inner wall  106 . The slot  102  provides access for a rod-removal tool to bend the end of the hinge rod toward the bottom surface so that it can be grasped and removed. The inner wall  106 , which presents a stop that is in line with and faces a line of hinge elements  108 , prevents the hinge rod from working its way out of the line of interleaved hinge elements during operation of the belt. Because the lateral extent and the area of the bottom surface of the thickened outer region  96  are greater than those of the hinge elements  108 , the bottom surface can serve as a wear pad that rides on a carryway wearstrip. 
     Yet another version of an edge module  110  with a thickened outer region  112  and usable in a conveyor belt as in  FIG. 4  is shown in  FIGS. 6A and 6B . The bottom surface  114  of the thickened outer region  112  has a lateral extent and an area greater than those of the hinge elements  116  to make it effective as a wear pad. A ramp  118 , which may be concavely curved as in  FIG. 6A , flat, or concavely piecewise flat, extends from the bottom surface  114  toward the deck  118 . The ramp  118  is in line with and faces the hinge elements  116  along one end of the module. The ramp  118  provides a slide surface along which the end of a hinge rod can slide when pushed out through the hinge elements  116  during manual removal. 
       FIG. 7  shows a portion of a conveyor belt  120  constructed of the belt modules  60  shown in  FIG. 2A . The belt  120  is shown engaged by a reversing element  122 , such as a full-width drive or idle sprocket or drum around which the belt reverses direction from an upper carryway to a lower return. The full-width reversing element  122  is typically mounted in a fixed lateral position relative to a conventional conveyor frame (not shown). The outer cylindrical periphery of the reversing element  122  has circumferentially spaced lateral grooves  124  across its width sized to receive the belt ribs  32 . At opposite sides of the reversing element  122 , the grooves open at their ends into edge recesses  126  sized to receive the bottom surfaces of the thickened outer edge portions  68  of the belt modules  60 . In this version the shape of the grooves  124  and the edge recesses  126  is complementary to the shape of the modules&#39; outer edge portions  68  and ribs  32 . The bottom surfaces of the thickened outer edge portions  68  of the belt  120  are confined in the edge recesses  126  to limit the lateral wander of the belt along the reversing element  122 . In that way the reversing element  122  keeps the belt  120  on track in the conveyor frame. 
     Although the invention has be described in detail with respect to a few illustrative versions used to describe features of the invention, other versions are possible. For example, the lateral ribs or drive bars on the bottoms of the belt modules are shown as continuous and joining the thickened outer edge portions in all the versions. But the ribs could be divided into segments across gaps or could be separated from the thickened outer edge portions by gaps. And complementary reversing-element peripheries that mate with the bottoms of belt modules other than those in  FIG. 7 , such as the other modules described in detail, could be made to make a conveyor with full-width reversing elements that track a conveyor belt.