Patent Description:
The invention relates to an apparatus for joining together two ends of a conveyor belt and, more particularly, to a portable splice press apparatus for joining together two ends of a conveyor belt.

Several industries utilize conveyor belts for transporting loads from one location to another location or for passing loads through successive processing operations. Many of these applications require conveyor belts that are able to maintain cleanliness under various and sometimes harsh conditions. For example, in the food and dairy industries, conveyor belts must provide sanitary surfaces for conveying food and dairy products to minimize the potential for contaminating these products. To meet this need, conveyor belt surfaces are often formed of materials, for example thermoplastic materials, that do not become easily contaminated when contacted with food or dairy products on the conveyor belt surface. To provide additional stability, light to medium duty conveyor belts used in these applications are typically formed in a plurality of plies, including one or more fabric layers sandwiched between thermoplastic or rubber layers. Thus, in the food product industry, for example, the conveying surface may be formed of a thermoplastic material that does not easily absorb liquid from conveyed food, while the carcass may be formed from a woven fabric to provide strength to the conveyor belt. In addition, in the food product industry and other industries, belts with uniform thicknesses and smooth continuous surfaces have greater strength, produce less wear on a conveyor system, and operate using smaller rollers than belts with non-uniform thicknesses or non-continuous surfaces.

During installation and maintenance of conveyor belts, the ends of one or more conveyor belts often must be joined together. While several existing methods and tools are capable of joining belt ends together, such as using adhesive or mechanical fasteners to adjoin the belt ends, welding is often the preferred method of joining the ends of conveyor belts, including light to medium duty polyvinyl chloride (PVC), polyurethane, and polyester belts, because it generally provides a more uniform and continuous joint and surface than other methods.

Welding ends of a conveyor belt together typically includes preparing the ends of the belt for splicing in a generally overlapping or intermeshing pattern, positioning the prepared belt ends together in a generally end-to-end orientation between a pair of heated plates, and subjecting the belt ends to specific temperatures and pressures applied by one or both of the plates for a specific amount of time to cause the material in the belt ends to melt or soften and flow together. Upon subsequently cooling the belt ends and releasing the pressure therefrom, the material will re-harden, fusing the material of the two belt ends to join the belt ends together. However, prior splice presses may have several deficiencies that limit usage of the splice presses.

Firstly, some prior splice presses are electrically inefficient. For example, some prior splice presses have thick metal platens, e.g., <NUM> thick, and a substantially rigid insulating member of heat insulating material between the platens of the splice press and the belt ends. This substantially rigid member may provide a more desirable heat distribution across the belt ends including a center hot zone and laterally outer cool zones.

Thick platens and an insulating member, however, increase the amount of mass that must be heated within the system because the entire thickness of the platens and the insulating member must be heated. Because more heat must be provided in order to sufficiently heat the belt ends, this additional heat must also be removed by the system prior to performing a subsequent splice, increasing the cycle time of the press for each belt splicing operation. Further, in some environments only relatively low voltage outlets, e.g., 110V, is available. There may simply not be sufficient power available to fully heat these prior splice presses because of the energy consumed in heating the thick platens and insulating member.

Another disadvantage of thick platens and a substantially rigid insulating member of prior splice presses is that they may increase the time required for heating the belt engaging surfaces of the splice press and for removing heat after the splice is formed. This delay decreases the ability of the user to quickly apply and remove heat from the belt ends. As a result, the quality of the splice may suffer because the quality of the splice depends on the temperature of the heated surfaces applied to the belt ends and the amount of time the belt ends are exposed to the temperature. For example, conveyor belt ends heated for too long of a duration may cause may undesirable amounts of material flow and/or degradation of the belt material. For a thermoplastic material belt with a fabric layer, this undesirable material flow could include bleeding of the thermoplastic material through the fabric layer of the belt which can create an area of high friction for the belt. Thus, the ability to quickly cool down the surfaces of the splice press can affect the resulting quality of the splice. <CIT> discloses a heat press for joining the spliced ends of a conveyor belt. The press includes an upper platen and a cooperating lower platen. The upper platen contains a flexible inflatable bladder that when inflated, is positioned to engage the upper surface of the belt, and urge the belt downwardly against the lower platen. The lower platen, which supports the belt, includes an electric heating element, that is supported on a block or heat sink formed of a metal, such as aluminum, and having a plurality of generally parallel internal flow channels. A layer of insulating material is located beneath the aluminum heat sink, as well as along the side edges of the heat sink.

The present invention relates to a portable conveyor belt splicing apparatus comprising the features as defined in claim <NUM>. Further embodiments of the portable conveyor belt splicing apparatus are subject to the dependent claims. In one aspect of the present disclosure, a portable conveyor belt splicing apparatus is provided for joining together ends of a conveyor belt. The portable conveyor belt splicing apparatus includes first and second press assemblies and elongated platens of the first and second press assemblies for being clamped on belt ends to longitudinally extend widthwise across conveyor belt ends. The portable conveyor belt splicing apparatus further includes heaters of the first and second press assemblies operable to heat the platens and at least one bladder of the first press assembly being inflatable to increase the clamping force applied to the belt ends by the platen of the first press assembly, the at least one bladder having a pair of opposite ends and extending longitudinally therebetween. The first press assembly also includes at least one first fan assembly of the first press assembly intermediate and spaced from the ends of the bladder for directing air past the bladder transverse to the longitudinal extent thereof and toward the platen of the first press assembly for cooling the platen.

In one form, the apparatus further comprises at least one second fan assembly of the second press assembly configured to direct air toward the platen of the second press assembly and cool the platen. In another form, the at least one bladder includes a pair of longitudinally extending bladders and the at least one fan assembly is configured to direct air past the bladders transverse to the longitudinal extents thereof.

In another aspect, a portable conveyor belt splicing apparatus is provided for joining conveyor belt ends together. The portable conveyor belt splicing apparatus includes upper and lower press assemblies and upper and lower platen assemblies of the upper and lower press assemblies. The apparatus includes a heater of one of the upper and lower platen assemblies of one of the upper and lower press assemblies. The one press assembly includes an insulating assembly having a plurality of resilient members of metallic material supporting the one platen assembly. In one form, the resilient members include coil springs.

The present disclosure also provides a conveyor belt splicing apparatus for joining ends of a conveyor belt. The conveyor belt splicing apparatus includes a housing including upper and lower housing portions having unclamped and clamped positions relative to ends of a conveyor belt. The upper and lower housing portions include upper and lower platens for being clamped on the belt ends with a clamping force with the upper and lower housing portions in the clamped position. The apparatus includes a heater associated with one of the housing portions for heating the platen thereof and at least one first bladder and at least one second bladder associated with the one housing portion and being inflatable to increase the clamping force the platen of the one housing portion applies against the belt ends. The apparatus includes a gap between the at least one first bladder and the at least one second bladder and at least one fan assembly associated with the one housing portion and arranged to direct airflow through the gap between the at least one first bladder and the at least one second bladder toward the platen of the one housing portion to cool the platen.

In another aspect of the present disclosure, a portable conveyor belt splicing apparatus is provided that includes upper and lower platens for clamping belt ends therebetween and upper and lower heaters operable to heat the upper and lower platens. The apparatus further includes a power supply circuit operably coupled to the upper and lower heaters for energizing the upper and lower heaters to splice the belt ends, the power supply circuit adapted to be electrically connected to either one of a high power standard power supply and a low power standard power supply. The power supply circuit is configured such that predetermined dwell characteristics for a belt splicing operation generated by the energized upper and lower heaters are the same regardless of whether the power supply circuit is connected to the high power standard power supply or the low power standard power supply.

In one form, the dwell characteristics include a dwell time such that the upper and lower platens are heated for a dwell time that is the same regardless of whether the power supply circuit is connected to the high power standard power supply or the low power standard power supply.

The dwell characteristics may include dwell temperatures for the upper and lower platens such that the upper and lower platens each have a dwell temperature that is the same regardless of whether the power supply circuit is connected to the high power standard power supply or the low power standard power supply.

In one form, the conveyor belt splicing apparatus further includes an air pump and at least one inflatable bladder connected to the air pump and the dwell characteristics include a dwell pressure. The power supply circuit is configured to control operation of the air pump to inflate the at least one bladder and apply the dwell pressure to the belt ends that is the same whether the power supply circuit is connected to the high power standard power supply or the low power standard power supply.

The power supply circuit of the conveyor belt splicing apparatus may be configured to operate the upper and lower heaters according to a first warm-up mode in response to the power supply being connected to the high power standard power supply. The power supply circuit may also be configured to operate the upper and lower heaters according to a second warm-up mode in response to the power supply being connected to the low power standard power supply. The second time period may be longer than the first time period.

In yet another form, the power supply circuit of the conveyor belt splicing apparatus is configured to alternate between providing more power to the upper heater than the lower heater and providing more power to the lower heater than the upper heater during a warm-up stage of a splicing operation in response to the power supply circuit being connected to the low power standard power supply. In one form, the power supply circuit is configured to provide more power to the upper heater than the lower heater by providing power to the upper heater and not providing power to the lower heater. The power supply circuit may also be configured to provide more power to the lower heater than the upper heater by providing power to the lower heater and not providing power to the upper heater.

In accordance with another aspect of the present disclosure, a method is provided for splicing ends of a conveyor belt between a pair of platens of a portable conveyor belt splicing apparatus. The method includes receiving electrical power at a power supply circuit of the conveyor belt splicing apparatus from either one of a high power standard power supply or a low power standard power supply. The method further includes energizing heaters operably coupled to the power supply circuit to heat the platens and splice the conveyor belt ends such that predetermined dwell characteristics generated by the heaters are the same regardless of whether the power supply circuit receives electrical power from the high power standard power supply or the low power standard power supply.

In <FIG> and <FIG>, a portable belt splicing apparatus such as splice press <NUM> is provided for joining ends <NUM>, <NUM> of a conveyor belt <NUM>. The splice press <NUM> includes upper and lower press assemblies <NUM> and <NUM> that include corresponding oppositely facing upper and lower platen assemblies <NUM>, <NUM>. As shown in <FIG>, the upper and lower platen assemblies <NUM>, <NUM> include upper and lower platens <NUM>, <NUM> and heaters <NUM>, <NUM> configured to heat the platens <NUM>, <NUM>. The splice press <NUM> has an on-board control system, such as a power supply circuit <NUM> (see <FIG>), which can be coupled to different power supplies and provides sufficient power to the heaters <NUM>, <NUM> and heat the platens <NUM>, <NUM> to cause the material of the conveyor belt ends <NUM>,<NUM> to begin to melt even when the power supply available to the splice press <NUM> is limited, such as <NUM> volt <NUM> amp; <NUM> volt, <NUM> amp; and <NUM> volt, <NUM> amp power supplies.

With reference to <FIG>, one or both of the upper and lower press assemblies <NUM>,<NUM> have insulating assemblies <NUM>, <NUM> which increase the efficiency of the platens <NUM>, <NUM> by resisting heat loss away from the platens <NUM>, <NUM>. Stated differently, the insulating assemblies <NUM>, <NUM> keep the heat generated by the heaters <NUM>, <NUM> at the platens <NUM>, <NUM>. This permits the platens <NUM>, <NUM> to be sufficiently heated even when the power available to the power supply circuit <NUM> is relatively low. Further, the insulating assemblies <NUM>, <NUM> may decrease the duration of heat application to the conveyor belt ends <NUM>, <NUM> which improves splice quality.

In one form, the insulating assemblies <NUM>, <NUM> reduce heat transfer from the upper and lower platen assemblies <NUM>, <NUM> by using standing air as an insulator and minimizing the surface area of material of the insulating assemblies <NUM>, <NUM> that contacts the platen assemblies <NUM>,<NUM>. With reference to <FIG>, the insulating assemblies include resilient support members, such as coil springs <NUM>, which include a plurality of coils <NUM>, each having a curved portion <NUM> that extends around a center <NUM> of the springs <NUM>. By resilient, it is intended to mean that the coil springs <NUM> are able to elastically deform during typical operation of the splice press <NUM>. The curved portions <NUM> include outer surfaces <NUM> that each form a point contact <NUM> with the platen assemblies <NUM>, <NUM> as shown in <FIG>. More specifically, the outer surfaces <NUM> may be rounded and contact generally flat support plates <NUM>, <NUM> of the upper and lower platen assemblies <NUM>, <NUM>. By utilizing point contacts, the area for conduction between the platen assemblies <NUM>, <NUM> and the springs <NUM> is minimized. The springs <NUM> also form point contacts with the spring beds <NUM>, <NUM> to minimize the area for conduction therebetween.

The support plate <NUM>, heater <NUM>, and platen <NUM> together form a flat body portion of the upper platen assembly <NUM>. Likewise, the support plate <NUM>, heater <NUM>, and platen <NUM> form a flat body portion of the lower platen assembly <NUM>. The springs <NUM> of the upper press assembly <NUM> are sufficiently strong to transfer force from inflatable bladders <NUM>, <NUM> against the flat body portion of the upper platen assembly <NUM> during a splicing operation. The springs <NUM> of the lower press assembly <NUM> are sufficiently strong to support the flat body portion of the lower platen assembly <NUM> against deflection during the splicing operation.

Additionally, the springs <NUM> may be made of a resilient material which permits some resilient, localized deflection of the platens <NUM>, <NUM>. This resilient, localized deformation allows the platens <NUM>, <NUM> to conform to the belt ends <NUM>, <NUM> and more evenly distribute clamp forces on the belt ends <NUM>,<NUM> and improves splice quality. The resilient coils <NUM> of the springs <NUM> may deform to a deflected configuration, such as by flattening out, and then elastically returning to a generally undeflected configuration, such as a more circular shape, after the loading from the splice operation has ended.

With reference to <FIG>, the springs <NUM> include air gaps <NUM> generally between the curved portions <NUM> as measured longitudinally along the spring bed as well as air gaps <NUM> (see <FIG>) between adjacent springs <NUM>. This way, each point contact <NUM> between the spring <NUM> and the support plates <NUM>, <NUM> is surrounded by a contiguous air gap roughly in the shape of a donut. While the springs <NUM> support or press against the platen assemblies <NUM>, <NUM> at the point contacts <NUM>, the air gaps <NUM>, <NUM> surrounding the point contacts <NUM> reduce the surface area for conductive heat transfer between the springs and the platen assemblies <NUM>, <NUM>.

The springs <NUM> may be compression springs having a helical shape. The springs <NUM> may be made from circular wire or wire having other cross-sectional shapes. In one form, the wire of the springs <NUM> has a circular cross section with a cross-sectional diameter of <NUM>. This relatively small cross section limits the conduction of heat through the material of the springs <NUM>. The springs <NUM> may be made from a metallic material, such as steel, spring steel, stainless steel. The material of the springs <NUM> may be selected to provide sufficient strength while providing a relatively low heat conduction to limit conductive heat transfer through the material of the springs <NUM>, such as stainless steel.

Returning to <FIG> and <FIG>, the splice press <NUM> includes clamps <NUM> that are used to clamp the upper and lower press assemblies <NUM> together on the conveyor belt ends <NUM>, <NUM> with a desired clamping force. The upper press assembly <NUM> has a pressure device <NUM> that is operated to apply further pressure, such as approximately two bar, to the platens <NUM>, <NUM> and increase the clamping force applied thereto. With reference to <FIG> and <FIG>, the springs <NUM> are secured in spring beds <NUM>,<NUM> above and below the upper and lower platen assemblies <NUM>, <NUM>. Returning to <FIG> and <FIG>, the pressure device <NUM> includes the pair of inflatable bladders <NUM>, <NUM> positioned between an extruded upper frame <NUM> of the upper press assembly <NUM> and the spring bed <NUM>. Inflating the bladders <NUM>, <NUM> urges the spring bed <NUM> and springs <NUM> secured therein downwardly in direction <NUM>, which urges the support plate <NUM>, heater <NUM>, and platen <NUM> downwardly as well. In other forms, the pressure device <NUM> may be included in the lower press assembly <NUM>, both the upper and lower press assemblies <NUM>, <NUM> could include a pressure device, or neither of the upper and lower press assemblies <NUM>, <NUM> may have a pressure device.

With reference to <FIG>, the upper and lower press assemblies <NUM>,<NUM> each include a cooling system, such as forced air cooling systems <NUM>, <NUM> for cooling the platens <NUM>, <NUM> once the belt ends <NUM>, <NUM> have been subjected to the desired pressure, temperature, and duration for the particular belt ends <NUM>, <NUM>. The forced air cooling systems <NUM>, <NUM> rapidly cool the platens <NUM>, <NUM> which may improve splice quality by reducing the duration of a splicing operation. By more quickly cooling the platens <NUM>, <NUM>, the forced air cooling systems <NUM>, <NUM> also decrease the time it takes to perform splicing operations on multiple conveyor belts <NUM>.

The forced air cooling system <NUM> directs airflow through a gap <NUM> between the bladders <NUM>, <NUM> to cool the platen <NUM> as shown in <FIG>. The upper forced air cooling system <NUM> and bladders <NUM>, <NUM> thereby permit cooling of the platen <NUM> while at the same time providing the ability to apply a clamping force to the platen <NUM> by inflating the bladders <NUM>, <NUM>. This is an advantage over some prior systems where air cooling was only available for the platen not shifted by an inflatable bladder.

With reference to <FIG> and <FIG>, the upper forced air cooling system <NUM> includes a longitudinally extending air flow assembly <NUM> that supports fan assemblies <NUM> positioned above an elongate duct <NUM> in the gap <NUM>. The duct <NUM> is formed in part by portions of the frame <NUM> and the spring bed <NUM>, such as a larger channel 100A of the frame <NUM> and a smaller channel 100B of the spring bed <NUM>, and extends substantially the entire working length of the upper platen <NUM>. The channels 100A, 100B include a pair of upstanding walls <NUM>, <NUM> of the spring bed <NUM> nested within a pair of downwardly depending walls <NUM>, <NUM> of the frame <NUM>, as shown in <FIG> and <FIG>.

With reference to <FIG>, the channel 100A of the frame <NUM> includes a laterally extending wall <NUM> with openings <NUM> positioned between the bladders <NUM>, <NUM> that open into the duct <NUM>. The wall <NUM> includes lands 109A separating the openings <NUM>. The fan assemblies <NUM> are positioned above the lands 109A with portions of the fan assemblies <NUM> extending longitudinally over the adjacent openings <NUM>. In this way, a majority of the airflow from the fan assemblies <NUM> first impacts the lands 109A and imparts a longitudinal component of movement to the airflow so that it exits the openings <NUM> generally in directions 111A, 111B. This longitudinal component of airflow encourages longitudinal movement of air along the duct <NUM>.

With reference to <FIG>, the fan assemblies <NUM> include fans <NUM> rotatable about axes <NUM> oriented to draw cooler, ambient air into the air flow assembly <NUM> through screens <NUM> (see <FIG>). The fan assemblies <NUM> include electric motors to rotate the fans <NUM> and substantially cylindrical fan shrouds 82A extending around the fans <NUM>. Each fan shroud 82A includes an inlet opening at one end of the shroud 82A and an outlet opening at the other end of the shroud 82A. The fan shrouds assist in directing airflow through the fan assemblies <NUM> and improving the efficiency of the fans <NUM>.

During a cooling operation, the fan assemblies <NUM> direct airflow in directions 111A, 111B (see <FIG>) through the openings <NUM> of the frame channel 100A, longitudinally along the duct <NUM>, vertically outward in direction <NUM> through openings <NUM> (see <FIG> and <FIG>) of the spring bed <NUM>, into the volume generally occupied by the springs <NUM>, and against the support plate <NUM> (see <FIG>). With reference to <FIG>, once the air reaches the support plate <NUM>, the fan assemblies <NUM> push the air laterally in directions <NUM>, <NUM> between the coils <NUM> of adjacent springs <NUM>. Further, the springs <NUM> have central, longitudinal openings <NUM> with the curved portions <NUM> extending thereabout. The central openings <NUM> permit some air to flow longitudinally through the centers of the springs <NUM>. In this manner, the fan assemblies <NUM> direct air through openings <NUM> of the frame <NUM> and through openings <NUM> of the spring bed <NUM> which are both vertically aligned with a central, high temperature portion <NUM> of the upper platen <NUM> (see <FIG>) so that the air first removes heat from the high temperature portion <NUM>. The fan assemblies <NUM> then direct the air flow or laterally in directions <NUM>, <NUM> which reduces the temperature of the support plate <NUM>, heater <NUM>, platen <NUM>, and springs <NUM> as the air flow travels toward the periphery of the spring bed <NUM>.

Although the airflow through the insulating assemblies <NUM>, <NUM> has been discussed using the terms lateral and longitudinal for ease of discussion, it will be appreciated that the airflow through the insulating assemblies <NUM>, <NUM> may include components of both longitudinal and lateral movement as well as swirling or other movements. It is believed that the arrangement of the many walls and coils <NUM> of the springs <NUM> contributes to turbulent airflow within the insulating assemblies <NUM>, <NUM> which further increases the rate at which the forced air cooling systems <NUM>, <NUM> can remove heat from the platen assemblies <NUM>, <NUM>.

With reference to <FIG> and <FIG>, the forced air cooling system <NUM> of the lower press assembly <NUM> is similar to the forced air cooling system <NUM> of the upper press assembly <NUM> and is configured to direct air into the insulating assembly <NUM> and rapidly cool the lower platen <NUM> after a splicing operation. One difference between the forced air cooling systems <NUM>, <NUM> is that the forced air cooling system <NUM> of the lower press assembly <NUM> does not include a duct like duct <NUM> to direct airflow longitudinally before directing the airflow vertically into the insulating assembly <NUM>. Instead, the air cooling system <NUM> has fan assemblies <NUM> that direct airflow vertically upward into the insulating assembly <NUM> rather than having an intervening duct as in the forced air cooling system <NUM>. However, in some applications, the forced air cooling system <NUM> may include a duct similar to duct <NUM> if desired.

The forced air cooling system <NUM> includes an airflow assembly <NUM> having a shroud <NUM> that contains fan assemblies <NUM>. The lower press assembly <NUM> has an extruded, lightweight frame <NUM> (see <FIG>) with an internal cavity <NUM> that receives the shroud <NUM> and fan assemblies <NUM> therein. In one approach, the shroud <NUM> and fan assemblies <NUM> may be slid longitudinally into the cavity <NUM> during assembly of the lower press assembly <NUM>. Further, the shroud <NUM> may be slid longitudinally outward from the cavity <NUM> during disassembly of the lower press assembly <NUM> which makes maintenance easier.

With reference to <FIG>, the lower frame <NUM> includes a support portion, such as a spring bed portion <NUM> that receives springs <NUM> which support the lower platen assembly <NUM>. With reference to <FIG>, the lower frame <NUM> has openings <NUM> and the fan assemblies <NUM> are generally aligned with the openings <NUM>. The shroud <NUM> includes a vent <NUM> at each of the ends of the splice press <NUM> as shown in <FIG>. With reference to <FIG>, the vents <NUM> are not covered by the belt ends <NUM>, <NUM> when the belt ends <NUM>, <NUM> are clamped between the upper and lower platen assemblies <NUM>, <NUM>. Rather, the vents <NUM> are uncovered and permit the fan assemblies <NUM> to draw cooler, ambient air in direction <NUM> into the ends of the shroud <NUM> and toward the fan assemblies <NUM>.

Turning to <FIG>, the fan assemblies <NUM> draw air within the shroud <NUM> up through the openings <NUM> of the frame <NUM> and direct the air into the insulating assembly <NUM>. The fan assemblies <NUM> direct the air vertically upward in direction <NUM> through the springs <NUM> and against the support plate <NUM> of the lower platen assembly <NUM>. The fan assemblies <NUM> and the openings <NUM> of the frame <NUM> are generally aligned with a central, high-temperature portion <NUM> (see <FIG>) of the lower platen <NUM>. The fan assemblies <NUM> thereby cause the air to remove heat first from the central portion <NUM> before traveling longitudinally <NUM>, <NUM> and laterally <NUM>, <NUM> away from the openings <NUM> toward the periphery of the spring bed <NUM>.

Returning to <FIG>, the spring bed <NUM> includes channels <NUM> that receive the springs <NUM>. The channels <NUM> include walls <NUM> extending along the spring bed <NUM> that separate the springs <NUM> and resist lateral movement of the springs <NUM>. The channels <NUM> include a center channel 220A with the openings <NUM> therein, the channel 220A having lands <NUM> that separate the openings <NUM> along the channel 220A. The walls <NUM> of the channel 220A and the lands <NUM> support the spring <NUM> received in the channel 220A while, at the same time, permitting airflow from the fan assemblies <NUM> to travel toward the upper platen assembly <NUM>.

With reference to <FIG> and <FIG>, the walls <NUM> have ends <NUM> and heights <NUM> that are shorter than the height or diameter <NUM> of the springs <NUM>. Because the wall height <NUM> is shorter than the spring diameter <NUM>, the wall ends <NUM> are spaced from the support plate <NUM> to resist conductive heat transfer from the support plate <NUM> to the spring bed <NUM>. The height <NUM> may be a portion of the diameter <NUM>, such as greater than one half of the diameter <NUM>, so that the walls <NUM> extend above the equator of the springs <NUM> to prevent a minimal amount of lateral movement of the springs <NUM>. As an example, the height or diameter <NUM> of the springs <NUM> may be approximately <NUM> and the wall heights <NUM> may be approximately <NUM>. In another form, the wall height <NUM> may be greater than three quarters the spring diameter <NUM>.

With reference to <FIG> and <FIG>, the spring bed <NUM> includes a pair of capture members <NUM> at the longitudinal ends of the spring bed <NUM> to retain the springs <NUM> within the channels <NUM>. In one approach, the springs <NUM> are compression springs and are compressed prior to inserting the springs <NUM> into each channel <NUM> between the capture members <NUM>. Because the springs <NUM> are under compression, the springs <NUM> are thereby restrained in longitudinal directions <NUM>,<NUM> against movement by the capture members <NUM>. Further, the walls <NUM> resist lateral movement of the springs <NUM> in directions <NUM>,<NUM>. To restrain the springs <NUM> against vertical movement, the channels <NUM> include walls <NUM> that support the upper portions of the springs <NUM> and the support plate <NUM> contacts the lower portions of the springs <NUM>, as shown in <FIG>. In this manner, the springs <NUM> are restrained between the spring bed <NUM> and the upper platen assembly <NUM>.

With temporary reference to <FIG>, the platens <NUM>, <NUM> have a longitudinal working length <NUM> for extending across the conveyor belt ends <NUM>, <NUM>. With reference to <FIG>, the springs <NUM> have a length <NUM> once the springs <NUM> have been secured in the spring bed <NUM>. In one approach, the spring length <NUM> is close to the working length <NUM> to provide support along the entire length of the working surfaces <NUM>, <NUM> (see <FIG> and <FIG>). Further, the springs <NUM> in the spring bed <NUM> have an overall lateral width <NUM> that is selected to be at least half, at least three quarters, or at least nine-tenths of a lateral width <NUM> of the platen <NUM> (see <FIG> and <FIG>). With reference to <FIG>, the lower platen <NUM> may be laterally wider than the upper platen <NUM> and the springs <NUM> of the lower press assembly <NUM> may have an overall lateral width 280A that is at least half, at least two-thirds, or at least three-quarters a lateral width 282A (see <FIG>) of the platen <NUM>. The springs <NUM> thereby provide support for the majority of the surface area of the platens <NUM>, <NUM> while at the same time resisting heat loss from the platens <NUM>, <NUM>. As an example, the splice press <NUM> may have has the following dimensions:.

Turning to <FIG>, the capture members <NUM> are removably received in notches <NUM> formed in an upper side <NUM> and the walls <NUM> of the spring bed <NUM>. To install one of the capture members <NUM> into the spring bed <NUM>, the capture member <NUM> is advanced in direction <NUM> into the notch <NUM> until the capture member <NUM> contacts an end <NUM> of the notch <NUM> in the walls <NUM>. The end <NUM> restricts further movement of the capture member <NUM> in direction <NUM> and, once the springs <NUM> have been compressed and loaded into the channels <NUM> between the capture members <NUM>, the springs <NUM> urge the plates <NUM> against the longitudinal ends of the notches <NUM> which holds the plates <NUM> in the notch <NUM>.

With reference to <FIG> and <FIG>, the spring bed <NUM> of the lower frame <NUM> is similar in many respects to the spring bed <NUM> discussed above. For example, the spring bed <NUM> includes channels <NUM> with walls <NUM> having a height <NUM> that is less than the spring height or diameter <NUM>. This positions ends <NUM> of the walls <NUM> away from the support plate <NUM> of the lower platen assembly <NUM>. In this way, conductive heat transfer between the support plate <NUM> and the walls <NUM> is reduced which improves the efficiency of the lower platen assembly <NUM>.

With respect to <FIG> and <FIG>, some of the channels 300A have openings <NUM> that together form the opening <NUM> for the fan assemblies <NUM>. The walls <NUM> of the channels 300A extend uninterrupted over the openings <NUM> to provide lateral support for the springs <NUM> as the springs <NUM> extend across the openings <NUM>. Another similarity between the spring beds <NUM>, <NUM> is that the spring bed <NUM> includes a pair of capture members <NUM> received in notches <NUM> of the walls <NUM> as shown in <FIG>. The springs <NUM> are held compressed between the capture members <NUM> within the channels <NUM>.

With reference to <FIG> and <FIG>, the bladders <NUM>, <NUM> may be made from lengths of flat foldable hose, like a fire hose, and each end of the fire hose is held closed by a clamp <NUM>. The clamps <NUM> are secured to the upper frame <NUM> by fasteners and the clamps <NUM> may include upstanding walls <NUM> that limit longitudinal movement of the spring bed <NUM> as the bladders <NUM>, <NUM> inflate and deflate.

With reference to <FIG>, the pressure device <NUM> includes a compressor <NUM> operably coupled to the bladders <NUM>, <NUM>, that can inflate or deflate the bladders <NUM>, <NUM>. The compressor <NUM> is mounted on-board the frame <NUM> and is connected to the bladders <NUM>, <NUM> by tubing <NUM>, fittings <NUM>, and valves. As discussed in greater detail below, the splice press <NUM> includes a main controller <NUM> that, in one form, includes a pressure sensor <NUM> configured to detect the pressure within the bladders <NUM>, <NUM>. To deflate the bladders <NUM>, <NUM>, the pressure device <NUM> includes a valve <NUM>. In one form, the valve <NUM> has an actuator, such as a button 102A (see <FIG>), which a user presses when prompted by a screen <NUM>, lights, and/or a buzzer at the completion of a splice operation. The valves may also include a quick exhaust valve <NUM> and a relief valve 105A. In another form, the main controller <NUM> automatically operates the valve <NUM> to release the pressure from the bladders <NUM>, <NUM>.

As noted above, the clamps <NUM> secure the bladders <NUM>, <NUM> against longitudinal movement relative to the frame <NUM> and generally secure the bladders <NUM>, <NUM> to the frame <NUM>. Each of the bladders <NUM>, <NUM>, are also generally constrained to inflate in a predetermined manner by the frame wall <NUM>, a bladder support portion <NUM> of the spring bed <NUM>, and a lateral downwardly depending wall <NUM> of the frame <NUM>, and an upstanding wall <NUM> of the spring bed <NUM> as shown in <FIG>. The generally rectangular configuration of the frame wall <NUM>, the bladder support portion <NUM>, the frame wall <NUM>, and the spring bed wall <NUM> urge the bladders <NUM>, <NUM>, to have a maintain a rectangular shape when inflated which further encourages flattening of upper and lower portions <NUM>, <NUM> of the bladders <NUM>, <NUM> and a more even distribution of pressure against the spring bed <NUM>.

With reference to <FIG> and <FIG>, the upper platen assembly <NUM> includes the platen <NUM>, the heater <NUM>, and the support plate <NUM>, as discussed above. The upper platen assembly <NUM> also includes legs <NUM> that extend along the frame wall <NUM> and hook inwardly at a foot <NUM>. The foot <NUM> is configured to engage a stud <NUM> at each end <NUM>, <NUM> of the splice press <NUM> (see <FIG>). The engagement of the feet <NUM> of the legs <NUM> with the studs <NUM> captures the upper platen assembly <NUM>, the springs <NUM>, and the spring bed <NUM> against the upper frame <NUM>.

With reference to <FIG> and <FIG>, the lower platen assembly <NUM> includes the platen <NUM>, the heater <NUM>, and the support plate <NUM> as discussed above and further includes leg portions <NUM> that extend downwardly and then inwardly at feet <NUM>. The lower frame <NUM> includes channels <NUM> on opposite lateral sides thereof that receive the feet <NUM> of the platen leg portions <NUM>. The feet <NUM> extend under a lip <NUM> of the channel which secures the leg portions <NUM> relative to the lower frame <NUM>. In this manner, the lower platen assembly <NUM> is secured to the lower frame <NUM> which in turn secures the springs <NUM> received in the spring bed <NUM> vertically between the support plate <NUM> and the lower frame <NUM>.

With reference to <FIG> and <FIG>, the legs <NUM> of the upper platen assembly <NUM> include openings <NUM> that permit air flow which has traveled in directions <NUM>, <NUM> (see <FIG>) to exit the upper press assembly <NUM> after cooling the upper platen <NUM>. The openings <NUM> may be vertically positioned so that airflow can travel over the walls <NUM>, between the coils <NUM> of adjacent springs, and outward through the openings <NUM> without having to contort vertically. Likewise, the leg portions <NUM> of the lower platen assembly <NUM> have openings <NUM> that permit air flow to exit in direction <NUM> after cooling the lower platen <NUM> as shown in <FIG>.

With reference to <FIG>, the ends <NUM>, <NUM> may be releasably secured to the frames <NUM>, <NUM>. To service or otherwise disassemble the splice press <NUM>, one or both of the ends <NUM>, <NUM> may be removed from the upper and lower frames <NUM>, <NUM>. The upper and lower platen assemblies <NUM>, <NUM> may be slid longitudinally relative to the upper and lower frames <NUM>, <NUM> to disengage the upper and lower platen assemblies <NUM>, <NUM> from the upper and lower frames <NUM>,<NUM>. This permits removal of the springs <NUM> and, for the upper frame <NUM>, removal of the spring bed <NUM>.

With reference to <FIG>, the end <NUM> includes an upper end body <NUM> and a lower end body <NUM> that are connected respectively to the upper and lower frames <NUM>, <NUM>. The end <NUM> includes a user interface <NUM> that can be used to program, operate, or otherwise control the splice press <NUM>. The user interface <NUM> may provide prompts for a user to select desired temperatures and durations for the splice operation, and/or may allow the user to select the parameters from a pre-determined collection of options. The user interface <NUM> may include a variety of audio, visual, and tactile interfaces to receive information from or transmit information to the user. In one approach, the user interface <NUM> includes a screen <NUM> for displaying information, start and stop buttons <NUM>, <NUM>, and a navigation knob <NUM> of a rotary encoder <NUM> for navigating through menus displayed on the screen <NUM>. The user interface <NUM> may also include other types of interfaces, such as sensors, receivers or other devices. In one form, the splice press <NUM> includes a USB port <NUM> (see <FIG>) that can receive information from a USB drive, such as recipe information that may include temperatures, duration, pressure, and other parameters of the splice process. With reference to <FIG>, the power supply circuit <NUM> may include a main controller <NUM> with a memory that stores splice recipes that a user may select from.

With reference to <FIG>, the clamps <NUM> include an actuator <NUM> that is connected to the lower end body <NUM> at a pivot connection <NUM>. The actuator <NUM> includes a rotatable handle <NUM> and a link <NUM>. Once the conveyor belt ends <NUM>, <NUM> have been positioned onto the lower platen <NUM>, and the upper press assembly <NUM> has been positioned onto the conveyor belt ends <NUM>, <NUM>, the actuators <NUM> may be pivoted in direction <NUM> into slots <NUM> of the respective upper end body <NUM> (see <FIG>). This positions the handles <NUM> above cup portions <NUM> of the upper end body <NUM>, as shown in <FIG>. The user may then turn the handles <NUM> clockwise, which, by way of a threaded engagement with the links <NUM>, draws the handle <NUM> downward against the cup portion <NUM>. The user may continue to turn the handle <NUM> thereby engaging a lower end <NUM> of the handle <NUM> against the cup portion <NUM> of the upper end body <NUM>. This tightening of the handles <NUM> at each actuator <NUM> rigidly clamps the upper and lower press assemblies <NUM>, <NUM> together with the conveyor belt ends <NUM>, <NUM> therebetween.

With reference to <FIG> and <FIG>, the splice press <NUM> includes an electrical connector, such as a power cord <NUM>, configured to supply electrical power from a standard power supply, such as an electrical outlet, to the power supply circuit <NUM>. The end <NUM> of the splice press <NUM> includes a power cord interface, such as a connector <NUM>, which engages an interface, such as a connector <NUM>, of the power cord <NUM>. At the other end of the power cord <NUM> there is a mains power supply interface, such as a plug <NUM>, for being coupled to the mains power supply. For example, the plug <NUM> has prongs <NUM> that engage openings of an electrical outlet.

The splice press <NUM> may include a plurality of power cords <NUM> that correspond to different power sources. The plug <NUM> of each power cord <NUM> has a particular configuration that can be connected to a specific standard power supply. For example, the plug <NUM> of a first cord <NUM> may have prongs <NUM> arranged to be connected to a socket that provides singe-phase <NUM> volt, <NUM> amp power; a second cord <NUM> may have prongs <NUM> arranged to be connected to a socket that provides single phase <NUM> volt, <NUM> amp power. In another form, a single cord <NUM> can be used to connect the splice press <NUM> to different standard power supplies. For example, the plug <NUM> of the single cord <NUM> may be reconfigured to adjust the plug <NUM> to mate with different electrical outlets and send different amounts of power to the splice press <NUM>.

The end <NUM> of the splice press <NUM> also includes an electrical connector, such as an umbilical cord <NUM>, which electrically connects portions of the power supply circuit <NUM> received in the upper and lower frames <NUM>, <NUM>. The umbilical cord <NUM> has one end <NUM> that is permanently coupled to the electrical components within the upper frame <NUM>. The other end of the umbilical cord <NUM> includes an umbilical cord interface, such as connector <NUM>, which couples to a press interface, such as a connector <NUM>, mounted to the lower end body <NUM>. The connection between the umbilical cord connector <NUM> and the connector <NUM> permits power and control information to transfer between the portions of the power supply circuit <NUM> received in the upper and lower frames <NUM>,<NUM>.

In <FIG>, <FIG>, and <FIG>, the splice press <NUM> includes the power supply circuit <NUM> having an upper portion <NUM> and a lower portion <NUM> connected by electrical connectors or wires <NUM> of the umbilical cord <NUM>. The upper portion <NUM> includes a control portion <NUM> and a heater portion <NUM>, the control portion <NUM> monitoring and controlling the heater section <NUM>. The heater portion <NUM> includes the heater <NUM> of the upper platen assembly <NUM>. The heater <NUM> includes heating elements <NUM>, <NUM> that receive electrical power from the control section <NUM> via wires <NUM>. The heating elements <NUM>, <NUM> are electrically connected in parallel or in series depending on the power provided by the standard power supply, as discussed in greater detail below.

Similarly, the lower portion <NUM> of the power supply circuit <NUM> includes a control portion <NUM> that controls and monitors a heater portion <NUM>. The heater portion <NUM> includes the heater <NUM> of the lower platen assembly <NUM>. The heater <NUM> includes heating elements <NUM>, <NUM> that receive electrical power from the control section <NUM> via wires <NUM>. The heating elements <NUM>, <NUM> are electrically connected in parallel or series depending on the power provided by the standard power supply, as discussed in greater detail below.

The control portions <NUM>, <NUM> provide power to the heating elements <NUM>, <NUM> and <NUM>, <NUM> to heat the platens <NUM>, <NUM>. To measure the temperature of the platens <NUM>, <NUM>, the heater portions <NUM>, <NUM> include thermocouples <NUM>, <NUM>. The thermocouples <NUM>,<NUM> provide a mV signal to the control portions <NUM>, <NUM>. The control portions <NUM>, <NUM> use changes in the signal to determine the temperature being measured by the thermocouples <NUM>, <NUM>.

With continued reference to <FIG>, <FIG>, <FIG>, the control sections <NUM>, <NUM> each include a power controller <NUM>, <NUM>. The power controllers <NUM>, <NUM> control the application of heat to the platens <NUM>, <NUM> via the heaters <NUM>, <NUM> and the removal of heat from the platens <NUM>, <NUM> via the fan assemblies <NUM>, <NUM>. The power controllers <NUM>, <NUM> also have temperature inputs <NUM>, <NUM> which receive temperature reading from the thermocouples <NUM>,<NUM>.

The upper portion <NUM> of the power supply circuit <NUM> includes the main controller <NUM>, which controls the power controllers <NUM>, <NUM>. To store recipes for different belt materials and configurations, the main controller <NUM> has a memory that may be preprogrammed with recipes that the user can access by using the knob <NUM> to navigate through menus presented on the display <NUM>. A user may connect a USB drive having recipes stored in a memory thereof to USB port <NUM>. The main controller <NUM> is configured to retrieve the recipe information form the USB drive and transfer the recipe information to the memory of the main controller <NUM>. In yet another approach, the splice press <NUM> may include a network interface, such as a modem or wireless device, that can be connected to a remote resource over a network such as the internet and facilitate obtaining recipes from the remote resource.

The control sections <NUM>, <NUM> also each include a thermal fuse relay <NUM>, <NUM>, a solid state relay <NUM>, <NUM>, a series-parallel relay <NUM>, <NUM>, and fan circuits <NUM>, <NUM>. Once the belt ends <NUM>, <NUM> have been held at the desired temperature, pressure, and time the power controllers <NUM>, <NUM> may energize the fan circuits <NUM>, <NUM> to operate the fan assemblies <NUM>, <NUM> and cool the platens <NUM>, <NUM>.

The splice press <NUM> is powered by standard power sources by way of one or more power cords <NUM> as discussed above. With reference to <FIG> and <FIG>, the connector <NUM> of the lower press assembly <NUM> has electrical contacts <NUM> for being coupled to one of the electrical contacts <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> (see <FIG>) of one of the power cords <NUM>. Pins A1, A2, A3, A4, and B1 of the electrical contacts <NUM> transmit the electrical power from the power cord <NUM>. The standard power source may be any of a variety of standard wall outlets including single phase, <NUM> volt <NUM> amp; single phase, <NUM> volt <NUM> amp; single phase, <NUM> volt, <NUM> amp; single phase, <NUM> volt, <NUM> amp; three-phase, <NUM> volt, <NUM> amp; three-phase, <NUM> volt, <NUM> amp, and three-phase <NUM> volt. Other power sources can also be used.

The pins A1, A2, A3, A4, and B1 of electrical contacts <NUM> provide power to thermal fuse relays <NUM>, <NUM> and a power supply <NUM> of the lower portion <NUM> of the power supply circuit <NUM>. The power supply <NUM> receives high voltage power from the standard power source, which may be at <NUM>, <NUM>, or <NUM> volts alternating current (AC), and converts the high voltage power to low voltage power, such as <NUM> volt direct current (DC) or <NUM> volt DC.

With reference to <FIG> and <FIG>, the electrical contacts <NUM> of the connector <NUM> are designed to interact with the electrical contacts <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> of the connectors <NUM> of different power cables <NUM>. With reference to <FIG> and <FIG>, the connector <NUM> of each cable includes ten contacts, A1-A4 and B1-B6. Electrical contacts A1-A4 and B1 transmit power to the power supply circuit <NUM>. Electrical contacts B2-B6 of the connectors <NUM>, however, form a binary code designating the standard power source to which the cord <NUM> is configured to be connected. The binary code is formed by a certain combination of electrical connectors B3-B6 being connected when the connector <NUM> of the cord <NUM> is connected to the connector <NUM> of the lower press assembly <NUM>. More specifically, the connector <NUM> of each cord <NUM> has jumpers <NUM> connecting two or more of the electrical connectors B3-B6 of the connector <NUM> to the connector B2 of the connector <NUM>. To configure the power controllers <NUM>, <NUM> according to which cord <NUM> is connected to the power supply circuit <NUM>, the memory of the main controller <NUM> includes a lookup table <NUM> of <FIG> and permits the main controller <NUM> to determine the cord <NUM> connected to the power supply circuit <NUM> based on the binary code produced by the electrical connectors B3-B6 of the electrical contacts <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, or <NUM>. With reference to <FIG>, some binary numbers (e.g., <NUM>,<NUM>,<NUM>, <NUM>, <NUM>, and <NUM>) can be associated with different standard power supplies for unique applications of the splice press <NUM> or additional standard power supplies.

To determine the binary signal produced by the electrical connectors B3-B6, the electrical connector B2 is connected to ground and the connectors B3-B6 receive voltage from the power supply circuit <NUM>. The jumper <NUM> of the connector <NUM> connects one or more of the electrical connectors B3-B6 to the grounded electrical connector B2. Because the jumper <NUM> is connected to the one or more electrical connectors B3-B6, the voltage provided to the one or more electrical connectors B3-B6 is pulled to the ground. The resulting low voltage of the one or more electrical connectors B3-B6 is considered a logic "<NUM>" while the higher voltage of the electrical connectors B3-B6 not connected to the jumper <NUM> is considered a logic "<NUM>". As an example with reference to the arrangement of electrical contacts <NUM> in <FIG>, the power controller <NUM> determines the power assigned to the cable <NUM> by detecting: a "<NUM>" for the B3 electrical connector (the first column); a "<NUM>" for B4 electrical connector (the second column); a "<NUM>" for the B5 electrical connector (the third column); and a "<NUM>" for B6 (the fourth column). The power controller <NUM> can thereby determine that the electrical contacts <NUM> connected to the electrical contacts 1062are associated with a cord <NUM> for single phase, <NUM> volt, <NUM> amp standard power supplies. In another approach, voltage may be provided to pin B6 and a binary signal could be produced by using the jumper <NUM> to transfer the voltage to selected ones of the electrical connectors B3-B6.

With reference to <FIG> and <FIG>, the connector <NUM> of the umbilical cable <NUM> is releasably connectable to the connector <NUM> of the lower press assembly <NUM>. The umbilical cable <NUM> includes wires <NUM>. The wires <NUM> connected to electrical connections B3-B5 transmit data between the main controller <NUM> and the lower power controller <NUM>. The wires <NUM> connected to electrical contacts B1-B2 transmit low voltage DC power from the power supply <NUM> to the upper portion <NUM> of the power supply circuit <NUM>. Further, the wires <NUM> connected to electrical contacts A3-A4 transmit high voltage AC power from the electrical connections <NUM> to the upper portion <NUM>.

With reference to <FIG>, the power controllers <NUM>, <NUM> have power inputs <NUM>, <NUM>. The power inputs <NUM>, <NUM> receive low voltage DC power from the power supply <NUM>. The power controller <NUM> in the top control portion <NUM> receives the power through the wires <NUM> of the umbilical cable <NUM>.

The power controller <NUM> includes four power outputs <NUM>, <NUM>, <NUM>, <NUM> and an input <NUM> for a proximity sensor <NUM>. The power controller <NUM> likewise includes four power outputs <NUM>, <NUM>, <NUM>, <NUM> an input <NUM> which could be used to receive information from the proximity sensor <NUM> (but in the illustrated form power controller <NUM> is not coupled to the proximity sensor <NUM>). Each power output includes a positive or hot lead and a negative or neutral lead. The various power outputs of the power controllers <NUM>, <NUM> provide various functionality to the components of the splice press <NUM>. For example, the power controllers <NUM>, <NUM> can selectively energize outputs <NUM>, <NUM> to selectively energize the fan circuits <NUM>, <NUM> such as at the end of the belt splicing procedure in order to cool down the platens <NUM>, <NUM>. The power controllers <NUM>, <NUM> can also energize the fan circuits <NUM>,<NUM> when the power controllers <NUM>, <NUM> detect a temperature of one or both of the platens <NUM>, <NUM> above a predetermined temperature using the thermocouples <NUM>, <NUM>.

The power controller <NUM> operates an electrical circuit <NUM> of the compressor <NUM>. To inflate the bladders <NUM>, <NUM>, the main controller <NUM> sends a signal to the power controller <NUM>. The power controller <NUM> energizes the power output <NUM> and causes the compressor <NUM> to inflate the bladders <NUM>, <NUM>.

With reference to <FIG>, the power supply circuitry <NUM> includes thermal fuse relays <NUM>, <NUM> that are single pole single throw relays which are normally open. The coil of the thermal fuse relay <NUM> is powered by the <NUM> volt DC. The coil is grounded through the thermal fuses <NUM>. Contact 1040A of thermal fuse relay <NUM> is connected to electrical contact A3 of the umbilical cable <NUM>. Contact 1040B of thermal fuse relay <NUM> is connected to contact 1041A of the solid state relay <NUM>.

In operation, <NUM> volt DC power flows through the coil of the thermal fuse relay <NUM>, which closes the thermal fuse relay <NUM> so that contacts 1040A and 1040B are connected. If the temperature of the platen <NUM> exceeds a certain temperature, the thermal fuses <NUM> break, thus cutting off the ground connection. As a result, the thermal fuse relay <NUM> returns to its normally open state, and no longer provides power to the solid state relay <NUM>. In this manner, the thermal fuse relay <NUM> protects against overheating of the upper platen <NUM>.

The thermal fuse relay <NUM> operates in substantially the same manner as the thermal fuse relay <NUM>. High voltage DC power flows from the electrical contact A1, through the coil which is grounded through the thermal fuses <NUM>. When the lower platen <NUM> exceeds a certain temperature, the thermal fuses <NUM> break, cutting off the ground connection. As a result, the thermal fuse relay <NUM> returns to its normally open state, cutting off power to the solid state relay <NUM>. The thermal fuse relay <NUM> thereby protects against overheating of the lower platen <NUM>.

Thermal fuses <NUM>,<NUM> may, in one form, be a set of two fuses in series. Thermal fuses <NUM> could alternatively be a single fuse and would still operate in the same manner.

With reference to <FIG>, the solid state relays <NUM>, <NUM> are single pole single throw relays that are normally open. The coils of the solid state relays <NUM>, <NUM> are controlled by the power outputs <NUM>, <NUM> of the power controllers <NUM>,<NUM>. When power is provided to the coils of the solid state relays <NUM>, <NUM> by the power outputs <NUM>, <NUM>, contacts 1041A, 1041B and 1091A, 1091B are connected thus providing power to heating elements <NUM>, <NUM> and series-parallel relays <NUM>,<NUM>.

The series-parallel relays <NUM>, <NUM> are double-pole, double-throw relays. The coils of the series-parallel relays <NUM>, <NUM> are powered by power outputs <NUM>, <NUM> of the power controllers <NUM>, <NUM>. The series-parallel relays <NUM>, <NUM> each have five contacts 1042A-E and 1092A-E. Contacts 1042B, 1092B are connected to the high voltage AC power via the solid state relays <NUM>, <NUM>. In single phase systems, this is the hot lead, in <NUM>-phase systems it is a first phase. Contacts 1042A, 1092A and 1042C, 1092C are connected to the neutral lead or a second phase of the high voltage AC power. Contact 1042D, 1092D are connected to the heating element <NUM>, <NUM> not connected to the solid state relay <NUM>,<NUM>. Contact 1042E, 1092E are connected to the opposite end of both heating elements <NUM>, <NUM>, <NUM>, <NUM>.

When the coils of the series-parallel relays <NUM>, <NUM> are not powered by the power controllers <NUM>, <NUM>, contacts 1042A, 1092A are connected to contacts 1042D, 1092D. Contacts 1042B, 1092B; 1042C, 1092C; and 1042E, 1092E are unconnected. In this state, power flows from the solid state relays <NUM>, <NUM>, through the first heating elements <NUM>,<NUM>, then through the second heating elements <NUM>, <NUM> and back to the neutral lead of the power source through contacts 1042D, 1092D and 1042A, 1092A of the series-parallel relays <NUM>, <NUM>. Thus, in this state the heating elements <NUM>, <NUM> and <NUM>, <NUM> are in series.

When the coils of the series-parallel relays <NUM>, <NUM> are powered, contacts 1042B, 1092B are connected to contacts 1042D, 1092D and contacts 1042C, 1092C are connected to contacts 1042E, 1092E. In this state, power flows from the solid state relays <NUM>, <NUM>, through the first heating elements <NUM>, <NUM> and through the second heating elements <NUM>, <NUM> via the series-parallel relays <NUM>, <NUM>. The power then flows back to the neutral lead through the connection between contacts 1042E, 1092E and 1042C, 1092C. Thus, in this state the heating elements <NUM>, <NUM> and <NUM>,<NUM> are in parallel.

With reference to <FIG>, the power controller <NUM> powers the proximity sensor <NUM> via power outlet <NUM>. The proximity sensor <NUM> may include a series of reed switches mounted in the upper press assembly <NUM>, which interact with one or more magnets in the lower press assembly <NUM>. The proximity sensor <NUM> senses how close the upper press assembly <NUM> of the splice press <NUM> is to the lower press assembly <NUM>. The power controller <NUM> may operate a relay of the compressor <NUM> in response to the signal from the proximity sensor <NUM>. If there is too much distance between the upper and lower press assemblies <NUM>, <NUM>, the compressor <NUM> may be turned off. Further, the power controller <NUM> may not heat the platens <NUM>, <NUM> unless the two upper and lower press assemblies <NUM>, <NUM> are clamped together, which is determined by the proximity sensor <NUM>. In other forms, the proximity sensor can be replaced with capacitive sensors, inductive sensors, photoelectric sensors, and/or pressure sensors.

With reference to <FIG> and <FIG>, the power controller <NUM> has two inputs <NUM>, <NUM> connected to temperature sensors <NUM>, <NUM>. The temperature sensors <NUM>, <NUM> detect the temperature of the top platen <NUM> and transmit a signal corresponding to the temperature back to the power controller <NUM>. The temperature sensors <NUM>, <NUM> can be thermistors, infrared temperature sensors, thermocouples, resistance thermometers, or another kind of electrical temperature sensor. The temperature sensors <NUM>, <NUM> operate as another safety mechanism whereby the power controller <NUM> will turn off the heater elements <NUM>, <NUM> via the solid state relay <NUM> when the temperature of the upper platen <NUM> reaches a limit temperature.

The umbilical cord <NUM> permits two-way information flow between the upper and lower portions <NUM>, <NUM> of the power supply circuit <NUM>. For example, the information flow may be between the main controller <NUM> and the power controllers <NUM>, <NUM>. The umbilical cord <NUM> permits the main controller <NUM> of the upper portion <NUM> of the power supply circuit <NUM> to communicate with the power controller <NUM> of the lower portion <NUM> of the power supply circuit <NUM>.

With reference to <FIG>, the power controller <NUM> includes a power outlet <NUM> connected to a buzzer <NUM>. The buzzer is <NUM> used to emit sound to notify the user of certain states. For example, the buzzer <NUM> could sound when the belt splicing process is complete, or it could sound when the temperature of the platens <NUM>, <NUM> exceeds a certain threshold. In alternative embodiments, the buzzer <NUM> can include a light or be replaced by a light.

With reference to <FIG>, the main controller <NUM> includes a power input <NUM> receiving power from the umbilical cable <NUM>. The main controller <NUM> also includes two data ports <NUM>, <NUM> for communicating with the power controllers <NUM>, <NUM>. The main controller <NUM> further includes a USB interface <NUM> for receiving data from and transmitting data to a USB drive connected to the USB port <NUM>. For example, the USB port can be used to update the belt splicing apparatus <NUM> with new recipes.

With reference to <FIG>, the splice press <NUM> may have a variety of different embodiments including versions with different lengths. These versions include <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, and <NUM> with the version number generally corresponding to the working length of the splice press <NUM>. For example, the splice press <NUM> disclosed in <FIG> is considered a <NUM> press. <FIG> includes a table <NUM> that provides a summary of the different modes of operation of each of the different versions of the splice press <NUM>. Each column represents a different version of the splice press <NUM>. The modes of operation are dependent on the standard power supply connected to the splice press <NUM>, as shown by the different rows. The modes of operation include whether the heating elements <NUM>/<NUM> and <NUM>/<NUM> are placed in series or parallel and whether the power supply circuit <NUM> alternately energizes the upper and lower heaters <NUM>, <NUM>.

With reference to <FIG>, the power supply circuit <NUM> is configured to provide different heating of the upper and lower platens <NUM>, <NUM> during warm-up of the platens <NUM>, <NUM> in response to the standard power supply. The power supply circuit <NUM> is further configured to provide a dwell during the splicing operation that is based at least in part on dwell characteristics, such as dwell time, dwell temperatures of the upper and lower platens <NUM>, <NUM>, pressure applied by the bladders <NUM>, <NUM>, that are utilized regardless of the standard power supply available such that, for a given conveyor belt, a single recipe needs to be selected by a user. This makes the splice press <NUM> more intuitive and easy to use. The dwell stage of a splicing operation is primarily for soaking heat into the belt ends <NUM>, <NUM> after the platens <NUM>, <NUM> reach the predetermined dwell temperature. In general, the thicker the belt, the longer the dwell time. During the dwell stage, the material of the fingers (see <FIG>) of one of the belt ends <NUM>, <NUM> begins to flow and joins with the material of the fingers of the other belt ends <NUM>, <NUM>.

<FIG> contains two graphs, with graph <NUM> showing the average temperature profile of the platens <NUM>, <NUM> during a splicing operation when the splice press <NUM> is connected to a low power, <NUM> volt standard power supply. <FIG> also contains graph <NUM> showing the temperature profile of the platens <NUM>, <NUM> when the splice press <NUM> is connected to a higher power, <NUM> volt standard power supply. The temperature in <FIG> is shown in Celsius and the time is measured in minutes and seconds. As used herein, the terms high power standard supply and low power standard power supply are used to refer to the relative electrical power provided by different standard power supplies. Whether a standard power supply is high power or low power depends on the splice press itself. For example and with reference to <FIG>, the splice press <NUM> may be a <NUM> version and the splice press <NUM> discussed below may be a <NUM> version. While a single phase, <NUM> volt, <NUM> amp standard power supply may be a high power standard power supply for the <NUM> version, the single phase, <NUM> volt, <NUM> amp standard power supply may be a low power standard power supply for the <NUM> version. Further, a three phase, <NUM> volt standard power supply may be a high power standard power supply for the <NUM> version while the <NUM> version is not configured to receive power from such a power source.

For the graph <NUM>, the main controller <NUM> causes the power controllers <NUM>, <NUM> to alternately energize the heaters <NUM>, <NUM>, i.e., one after the other, during a warm-up mode or stage <NUM> of operation when the cord <NUM> is connected to the <NUM> volt standard power supply. For the graph <NUM>, however, the main controller <NUM> causes the power controllers <NUM>, <NUM> to energize both of the heaters <NUM>, <NUM> continuously and at the same time during a warm-up mode or stage 2200A when the cord <NUM> is connected to the <NUM> volt power standard power supply. In one approach, the main controller <NUM> may determine whether to utilize the alternating powering of the heaters <NUM>, <NUM> or the simultaneous powering of the heaters <NUM>, <NUM> in response to the result of the binary code look-up procedure discussed above with respect to <FIG> and <FIG>. In one approach, the available number of Watts determine whether the power supplied to the power supply circuit <NUM> is high or low.

In one form, the main controller <NUM> includes a microcontroller that alternates energizing the heaters <NUM>, <NUM> by adjusting the solid state relays <NUM>, <NUM> which control power to the heaters <NUM>, <NUM>. The adjusting of the relays causes more power to flow to one of the heaters <NUM>, <NUM> than the other. In one approach, alternating the heaters <NUM>, <NUM> involves providing power to the heater <NUM> while not providing power to the heater <NUM>, then providing power to the heater <NUM> while not providing power to the heater <NUM>. In other words, one heater <NUM> is turned off while the other heater <NUM> is turned on. As an example, the heater <NUM> may be energized for two seconds while the heater <NUM> is turned off for those two seconds, then the heater <NUM> is energized for two seconds while the hater <NUM> is turned off for those two seconds.

In another approach, the alternating of energizing the heaters <NUM>, <NUM> may involve providing a higher percentage (such as <NUM> percent) of the available power to one heater <NUM>, <NUM> while, at the same time, providing a smaller percentage (such as ten percent) of the available power to the other heater <NUM>, <NUM>. In this manner, the both heaters <NUM>, <NUM> are being energized but one is being energized more than the other.

Returning to <FIG>, the operation of the splice press <NUM> includes the warm-up stages 2200A, <NUM> until the platens <NUM>, <NUM> reach critical temperatures <NUM>, <NUM>. Due to the lower power available to the splice press <NUM> when the splice press is connected to the <NUM> volt standard power supply, i.e., graph <NUM>, platens <NUM>, <NUM> take longer to reach the critical temperature <NUM> as the main controller <NUM> alternates between energizing the heater <NUM> and the heater <NUM>. When the splice press <NUM> is connected to the <NUM> volt standard power supply, there is more power available to the splice press <NUM> such that the platens <NUM>, <NUM> reach the critical temperature <NUM> faster. Because the main controller <NUM> can alternately energize the heaters <NUM>, <NUM> when the splice press <NUM> is connected to a low power standard power supply, the splice press <NUM> can still raise the platens <NUM>, <NUM> to a dwell temperature <NUM> which causes the material of the belt ends <NUM>, <NUM> to melt despite the lower power available.

With reference to <FIG>, the temperature of the platens <NUM>, <NUM> begins at a starting temperature <NUM>, <NUM> and increases until reaching critical temperature <NUM>, <NUM>, which is the same for both graphs <NUM>, <NUM>, e. g, <NUM> degrees Celsius. Once the critical temperature <NUM> is reached in graph <NUM>, the main controller <NUM> continues alternately energizing the upper and lower heaters <NUM>, <NUM> to heat the upper and lower platens <NUM>, <NUM> at a rate <NUM>. By contrast, in graph <NUM> the main controller <NUM> energized both the upper and lower heaters <NUM>, <NUM> together prior to the platens <NUM>, <NUM> reaching the critical temperature <NUM> (hence the faster rate of heating than graph <NUM>). Once the critical temperature <NUM> is reached in graph <NUM>, the main controller <NUM> begins to alternately energize the upper and lower heaters <NUM>, <NUM>. This causes the platens <NUM>, <NUM> to heat at a slower rate 2202A than in the warm-up stage 2200A. Moreover, the main controller <NUM> operates the upper and lower heaters <NUM>, <NUM> to cause the rate 2202A to be approximate the rate <NUM>. Besides alternating energizing the upper and lower heaters <NUM>, <NUM>, the main controller <NUM> may also reduce the duration of each energization of the upper and lower heaters <NUM>, <NUM> to compensate for the higher power standard power supply and provide the similar rates 2202A, <NUM>.

With reference to <FIG>, the similarity in rates <NUM> and 2202A is shown by the "heat up time (<NUM>-<NUM>)" being <NUM> seconds for the <NUM> volt single phase and <NUM> seconds for the <NUM> volt single phase. By making the rates <NUM> and 2202A similar, the melting of the belt end material that begins at the dwell temperature <NUM>, <NUM> is more consistent and independent of the standard power supply available.

The main controller <NUM> continues to alternate between powering the upper and lower heaters <NUM>, <NUM> in both the low power graph <NUM> and the high power graph <NUM> until the platens reach the dwell temperature <NUM>, <NUM> which is the same for both graphs <NUM>, <NUM>, e.g., <NUM> degrees Celsius. The main controller <NUM> continues to alternate between powering the upper and lower heaters <NUM>, <NUM> as necessary to maintain the upper and lower platens <NUM>, <NUM> at the dwell temperature <NUM>, <NUM> for the dwell time <NUM>, <NUM>, which is the same for both graphs <NUM>, <NUM>, e.g., <NUM> minute. In one approach, the dwell mode or stage lasts from when the platens <NUM>, <NUM> reach temperatures <NUM>, <NUM>, for the dwell times <NUM>, <NUM>, and ends at temperatures <NUM>, <NUM>. In some approaches, the temperature of the platens <NUM>, <NUM> may vary during the dwell times <NUM>, <NUM>. The power supply circuit <NUM> may utilize a feedback loop using temperature sensors <NUM>, <NUM> (see <FIG> and <FIG>) to determine when to energize the upper and lower heaters <NUM>, <NUM>.

With continued reference to <FIG>, the main controller <NUM> maintains the platens <NUM>, <NUM> at the dwell temperatures <NUM>, <NUM> for the dwell time <NUM>, <NUM> set by the recipe until dwell end points <NUM>, <NUM> are reached and the heaters <NUM>, <NUM> are turned off. At this point, the cool-down stage 2200D, <NUM> starts. During the cool-down stages 2200D, <NUM>, the main controller <NUM> causes the power controllers <NUM>, <NUM> to energize the fan circuits <NUM>, <NUM> and operate the fan assemblies <NUM>, <NUM> to reduce the temperature of the platens <NUM>, <NUM>.

As noted above, <FIG> provides the graph <NUM> of temperature of the platens <NUM>, <NUM> during a splice operation when the cord <NUM> is connected to a high power standard power supply. For example, a user may have selected the cord <NUM> configured to be connected to three phase, <NUM> volt, <NUM> amp standard power supply. The connector <NUM> of this cord <NUM> includes the electrical contacts <NUM> (see <FIG> and <FIG>). Once the user connects the connector <NUM> to the connector <NUM> of the lower press assembly <NUM> and powers up the splice press <NUM>, the main controller <NUM> uses the lookup table of <FIG> and the binary code provided by the connector <NUM> to determine the phase, voltage, and current rating of the standard power supply.

As discussed above, the main controller <NUM> is configured to alternate between energizing the upper and lower heaters <NUM>, <NUM> during the warm-up stage when the splice press <NUM> is connected to a low power standard power supply, which permits the platens <NUM>, <NUM> to be heated to the critical temperature despite the low power. The main controller <NUM> is also configured to operate each pair of heating elements <NUM>, <NUM> and <NUM>, <NUM> in series or parallel during the splicing operation depending on the voltage of the standard power supply.

With reference to <FIG>, tables 2222A, 2222B, 2222C, are provided that includes data from the graph of <FIG> and corresponds to a single recipe used to splice a specific belt regardless of whether the splice press <NUM> is connected <NUM> volt single phase or <NUM> volt single phase. As an example, the recipe for splicing a particular conveyor belt may include the information in table 2222A. The information in table 2222A includes dwell characteristics such as a dwell temperature (the temperature of the upper and lower platens <NUM>, <NUM>), a dwell time (how long the main controller <NUM> keeps the platens <NUM>, <NUM> at the dwell temperature), and pressure to be applied by the bladders <NUM>, <NUM>. The information in the table 2222a can also include other information such as preheat/no preheat, for example. As can be seen by reviewing <FIG> and table 2222A, there is a single recipe for both the <NUM> volt single phase (see graph <NUM>) and the <NUM> volt single phase (see graph <NUM>). In particular, in both modes of operation the dwell temperature for both platens <NUM>, <NUM> is <NUM> degrees Celsius, the dwell time is one minute, the pressure applied by the bladders <NUM>, <NUM> is <NUM> bar, and there is no preheat operation. In simple terms, a user may select a recipe for a particular belt and the power supply circuit <NUM> takes care of the rest by alternately causing heating of the platens <NUM>, <NUM> if there is a low power standard power supply available and heating the plates <NUM>, <NUM> simultaneously if there is a high power standard power supply available. Once the plates <NUM>,<NUM> reach the dwell temperatures <NUM>, <NUM>, the power supply circuit <NUM> operates the heaters <NUM>, <NUM> to provide the same heating profile of the platens <NUM>, <NUM> during the dwell time <NUM>, <NUM> whether there is a lower power or a high power standard power supply available. It is noted that a particular conveyor belt may be a conveyor belt made of a specific material(s) and having a specific thickness and width. As an example, for a certain thermoplastic belt material, each size belt may have a different recipe. In other approaches, the dwell temperatures for the platens <NUM>, <NUM> may be different such as the dwell temperature of the upper platen <NUM> being higher than the dwell temperature of the lower platen <NUM>.

Initially, the series-parallel relays <NUM>, <NUM> are in a safe series mode with the heating elements <NUM>, <NUM> being connected in series and the heating elements <NUM>, <NUM> being connected in series. When the splice press <NUM> is connected to a high voltage standard power supply, the relays <NUM>, <NUM> remain unpowered, resulting in the heating elements <NUM>,<NUM> being connected in series and the heating elements <NUM>, <NUM> being connected in series.

When the splice press <NUM> is connected to a low voltage standard power supply, the relays <NUM>, <NUM> are energized. This causes the heating elements <NUM>, <NUM> to be connected in parallel and the heating elements <NUM>,<NUM> to be connected in parallel. This allows each heating element <NUM>, <NUM>, <NUM>, <NUM> to experience the same, or nearly the same, voltage drop whether there is a lower voltage or higher voltage standard power supply available. As an example, the voltage drop across each of the heating elements <NUM>, <NUM>, <NUM>, <NUM> is <NUM> volts when the splice press <NUM> is connected to a <NUM> volt power supply and the heating element <NUM>, <NUM> and <NUM>, <NUM> are in parallel as well as when the splice press <NUM> is connected to a <NUM> volt power source and the heating elements <NUM>, <NUM> and <NUM>, <NUM> are in series.

With reference to <FIG>, the table <NUM> of different models of the splice press <NUM> described in the present application at different standard power supplies. The table indicates whether the apparatus can operate at a particular power and, if so, whether the heating elements <NUM>, <NUM> and <NUM>, <NUM> are in series or parallel during a splicing operation and if the splice press <NUM> needs to alternate heating between the upper and lower platens <NUM>, <NUM> during warm-up. The electrical schematic of <FIG> is representative of the <NUM>, <NUM>, and <NUM> versions of the splice press <NUM> identified in table <NUM>.

In <FIG>, another splice press <NUM> is provided that is the <NUM> version identified in the table <NUM> of <FIG>. The splice press <NUM> is similar in many respects to the splice press <NUM> discussed above. The splice press <NUM> has a platen working length <NUM> of approximately <NUM> which is longer than the working length <NUM> of the splice press <NUM> discussed above.

With reference to <FIG>, another difference between the splice presses <NUM>, <NUM> is that the splice press <NUM> includes pairs of vertically stacked bladders <NUM>, <NUM> and <NUM>, <NUM> that can be inflated to urge apart a frame <NUM> and a spring bed <NUM> of the splice press <NUM>. In some applications, the frame <NUM> of a longer splice press may deflect more in the longitudinal middle of the frames <NUM> than the frame of a shorter splice press. The bladders for these longer splice presses may therefore have a longer vertical stroke than the bladders of the shorter presses. Utilizing two pairs of bladders <NUM>, <NUM> and <NUM>, <NUM> is advantageous for the longer splice presses because each bladder has a shorter stroke than if there were only one bladder on each side. Because each bladder has a shorter stroke, each one of the bladders <NUM>, <NUM>, <NUM>, <NUM> is less curved in cross section than if there were only one bladder. The decreased curvature improves the distribution of pressure against the spring bed <NUM> and improves splice quality by reducing hot spots that may occur along the conveyor belt ends during the splicing operation.

With reference to <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, the splice press <NUM> has a power supply circuit <NUM> that is similar in many respects to the power supply circuit <NUM> of the splice press <NUM>. The electrical schematic for the of <FIG> is representative of the <NUM>, <NUM>, and <NUM> versions of the splice press identified above in the table <NUM> of <FIG>.

Claim 1:
A portable conveyor belt splicing apparatus (<NUM>) for joining conveyor belt ends (<NUM>, <NUM>) together, the portable conveyor belt splicing apparatus (<NUM>) comprising:
upper and lower press assemblies (<NUM>, <NUM>);
upper and lower platen assemblies (<NUM>, <NUM>) of the upper and lower press assemblies (<NUM>, <NUM>);
a heater (<NUM>, <NUM>) of one of the upper and lower platen assemblies (<NUM>, <NUM>) of one of the upper and lower press assemblies (<NUM>, <NUM>); and
an insulating assembly (<NUM>, <NUM>) of the one press assembly (<NUM>, <NUM>) including a plurality of resilient members (<NUM>) of metallic material supporting the one platen assembly (<NUM>, <NUM>),
wherein the plurality of resilient members (<NUM>) each include a plurality of curved portions (<NUM>) that are spaced from each other and form spaced contacts with the one platen assembly (<NUM>, <NUM>).