Patent Description:
Flatwire conveyor belts, which are typically constructed from metal strips (e.g., pickets or wickets) that are interconnected with cross-rods, continue to have applicability for a variety of conveying applications. The construction of flatwire conveyor belts offers an efficient strength-to-weight ratio that is relatively cost-effective to manufacture. One disadvantage of conventional flatwire conveyor belts relates to the relative openness of the conveying surface, which presents challenges for transporting product of a size and/or form factor that is incompatible with the relatively open conveying surface. For example, conventional construction establishes larger open areas that can hamper effective carrying of correspondingly smaller products (e.g., products may pass partially through, become entangled with, or be unstable on the conveying surface). Conventional construction can also inhibit a smooth, continuous transfer of product both on to and off of the flatwire conveyor belt.

In addition, during use, conventional flatwire conveyor belts may have a tendency, in particular applications, to shift or wander laterally relative to a conveying direction. The metal strip construction of current flatwire conveyor belts presents practical challenges of effectively and efficiently controlling and/or reducing undesirable lateral movement of the flatwire conveyor belt.

Publications <CIT>, <CIT> and <CIT> discloses a module capable of use in a flatwire conveyor belt assembly. The module comprises a picket having leading links and trailing links. The picket defines a picket leading portion proximate the leading links and a picket trailing portion proximate the trailing links. The module further comprises a top plate having a leading end and a trailing end and defining a top plate leading portion proximate the leading end and a top plate trailing portion proximate the trailing end. Additionally, <CIT> discloses a clip having multiple tabs configured to receive adjacent transverse conveyor bars. Publication <CIT> further discloses cover plates having fingers configured to engage pintle rods. Publication <CIT> includes plastic pieces connected to a metal body.

Therefore, a need exists for an improved flatwire conveyor belt system that maintains the conventional features and benefits, while addressing various deficiencies associated with the implementation and operation of flatwire conveyor belt assemblies.

Thereto, the invention provides for a module of use in a flatwire conveyor belt assembly, in particular the module according to claim <NUM>. Additionally, the invention provides for a flatwire conveyor belt system, in particular the flatwire conveyor belt system according to claim <NUM>. The dependent claims concern particular embodiments of the invention as claimed in independent claim <NUM> or independent claim <NUM>.

The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals.

The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention.

Several rows of a flatwire conveyor belt <NUM> in accordance with one example embodiment are depicted in <FIG> and <FIG>. The flatwire conveyor belt <NUM> is typically an endless belt driven in a direction of travel (designated by arrow D), and constructed to address particular application requirements. Each row <NUM> includes a picket <NUM> that supports multiple modular top plates <NUM>. Adjacent rows <NUM> are interconnected by a cross-rod <NUM> that extends laterally (relative to the direction of travel D) through the pickets <NUM> and the top plates <NUM>, generally forming a hinge connection. In use, the cross-rods <NUM> are typically engaged by one or more sprockets driven by a motor that rotates the sprocket(s) to engage and drive against the cross-rods <NUM> from beneath the flatwire conveyor belt <NUM>. In the example shown, the cross-rod <NUM> is metallic with ends <NUM> that are formed or mushroomed to limit lateral movement (i.e., in a direction generally skewed to the direction of travel D) of the cross-rod <NUM> once adjacent rows <NUM> are interconnected. In alternative embodiments, other restraint mechanisms can be used to restrain the cross-rod, such as collars or clips, and the cross-rod can be constructed of non-metallic materials (e.g., plastics or composites).

The form factor of each picket <NUM> allows for adjacent pickets <NUM> to be interconnected and provides for interface features that allow the top plates <NUM> to be secured to, in some embodiments, both the picket <NUM> and the cross-rod <NUM>. The example picket <NUM> is shown and described with additional reference to <FIG>, and is typically manufactured and formed from a single metallic strip having a generally uniform cross-section. While the pickets <NUM> are shown to define a specific pitch P (i.e., a center-to-center distance between adjacent cross-rods <NUM>) and a specific opening width W (i.e., a nominal form to allow nesting and intermeshing of an adjacent picket <NUM>), the form factor of the picket <NUM> can be adapted to address application-specific requirements (e.g., weight of product, speed of conveyance, overall conveyor belt envelope constraints, etc.).

The example picket <NUM> includes edge links <NUM> that flank alternating leading links <NUM> and trailing links <NUM>. While the form factor of the edge links <NUM>, leading links <NUM>, and trailing links <NUM> can be generally uniform in particular applications, the edge links <NUM> in the example embodiment are narrower than the individual leading links <NUM> and trailing links <NUM>. Specifically, the edge links <NUM> define an edge end portion <NUM> that is approximately half the size of a leading end portion <NUM> of the leading link <NUM> or a trailing end portion <NUM> of the trailing link <NUM>. The leading links <NUM> and the trailing links <NUM> are generally U-shaped (as viewed in <FIG>) having pairs of leg portions <NUM> formed generally orthogonally to the respective leading end portion <NUM> and trailing end portion <NUM>. Adjacent leg portions <NUM> of laterally spaced leading links <NUM> and trailing links <NUM> are bridged by side bars <NUM> that, in the example embodiment, are skewed relative to the pairs of leg portions <NUM>.

The form of the example edge links <NUM> varies from the leading links <NUM> and the trailing links <NUM> in some respects. The edge end portion <NUM> of each edge link <NUM> is also generally U-shaped (as viewed in <FIG>) and defines an inner leg portion <NUM> and an outer leg portion <NUM> that are formed generally orthogonally to the edge end portion <NUM>. In the example embodiment, a side bar <NUM> bridges the inner leg portion <NUM> and a leg portion <NUM> of the outermost trailing link <NUM>. The outer leg portion <NUM> is bridged by a side bar <NUM> to an end bar <NUM> defined at a lateral side of the picket <NUM>. While the structure of the example picket <NUM> includes a certain level of uniformity and repeating patterns to aid in manufacturing of the picket <NUM> and construction of a flatwire conveyor belt <NUM>, alternative embodiments may diverge from that shown to, for example, address application-specific requirements and/or goals.

The example picket <NUM> includes a series of features that provide for interconnecting adjacent pickets <NUM> with cross-rods <NUM>, and for interfacing with and supporting the top plates <NUM>. When adjacent pickets <NUM> have been intermeshed, a cross-rod <NUM> can extend through generally similar openings <NUM> defined in the edge links <NUM>, the leading links <NUM>, and the trailing links <NUM>. The openings <NUM> of the example embodiment are not uniformly circular, but are somewhat oval and are positioned to extend through the corners formed between the edge end portion <NUM>, the leading end portion <NUM>, the trailing end portion <NUM>, and respective leg portions <NUM>. Similar openings <NUM> are formed in the edge bar <NUM> and are generally axially aligned with the openings <NUM> formed in the trailing links <NUM>. The form factor of the openings <NUM>, <NUM> can allow for a desired amount of slack between adjacent pickets <NUM>, generally in the direction of travel D. In addition, the form factor of the openings <NUM>, <NUM> can be tailored to accommodate a lateral compression of the picket <NUM> during assembly of multiple pickets <NUM> to form rows of a flatwire conveyor belt <NUM>, and to account for practical manufacturing tolerances and considerations associated with the installation and assembly of the top plates <NUM>.

The example pickets <NUM> define other interface features that are tailored to engage and support top plates <NUM>, such that when the flatwire conveyor belt <NUM> is traveling in a horizontal plane, the top plates <NUM> establish a generally continuous conveying surface <NUM> (e.g., see <FIG>). Each picket <NUM> defines a series of slots <NUM> formed in the edge end portion <NUM>, the leading end portion <NUM>, and the trailing end portion <NUM>. In the example embodiment, the slots <NUM> are generally rectangular with rounded corners and are positioned above a midpoint and closer to the top of the picket <NUM>. The edge end portions <NUM> are illustrated with a single slot <NUM> with each of the leading end portions <NUM> and the trailing end portions <NUM> defining two laterally spaced slots <NUM>. The example slots <NUM> can also comprise a single angled slot, one or more circular opening, protrusion, or other form factor configured to interact with the mating form factor provided in the top plate <NUM> (discussed below). The particular form factor and positioning of the slots <NUM> can be adapted and/or altered to accommodate application requirements, manufacturing constraints, or other considerations (e.g., the slots <NUM> may be adapted to interact with a mating top plate <NUM> to provide a biasing force urging the top plate <NUM> into engagement with the picket <NUM>). In the example embodiment, and as described below in more detail, the slots <NUM> formed in the trailing end portion <NUM> of the trailing links <NUM> engage with a mating structure of the top plate <NUM> to define an example picket trailing interface portion of a trailing interface. The trailing interface establishes selective engagement between the picket <NUM> and the top plate <NUM> proximate the trailing end of each.

An example leading interface establishes selective engagement between the picket <NUM> and the top plate <NUM> proximate the leading end of each, and a respective cross-rod <NUM>. The picket <NUM> defines openings <NUM> that can aid in positioning, assembling, and restraining the top plate <NUM> at an example picket leading portion of the leading interface. The openings <NUM> are generally cylindrical, axially aligned, and extend through the various leg portions <NUM> of the edge links <NUM> and the leading links <NUM>. The example openings <NUM> can also comprise, for instance, slots, protrusions, and notches, or any other form factor configured to interact with the mating form factor provided on the top plate <NUM> (discussed below). Another axially aligned set of openings <NUM> is formed in the edge bars <NUM> and the trailing links <NUM>. In one embodiment, the openings <NUM> are generally uniform in form factor and are positioned at a midpoint between the upper and lower bounds of the picket <NUM>.

Each example picket <NUM> also defines notches <NUM> that are generally formed in the edge end portions <NUM> of each edge link <NUM>, the leading end portion <NUM> of the leading link <NUM>, and the trailing end portion <NUM> of the trailing link <NUM>. The example notches <NUM> are formed in the upper portion of the edge links <NUM>, leading links <NUM>, and trailing links <NUM> and extend partially into respective leg portions <NUM> (and edge bars <NUM>) to provide clearance for the top plate <NUM> when the top plate <NUM> is seated on top of the picket <NUM>. In profile, as shown best in <FIG>, each notch extends nearly above a portion of a respective, relative opening <NUM>, <NUM>. The form factor and placement of the notches <NUM> can be adapted for a particular application, such as to accommodate a particular top plate design.

The form factor of the top plates <NUM> allow for each to be seated atop and interface with a supporting picket <NUM>, while also being captured to a cross-rod <NUM> installed to hingedly interconnect adjacent pickets <NUM>. The example top plate <NUM> is shown and described with additional reference to <FIG>. In one embodiment, the top plate <NUM> is manufactured and formed from a metallic sheet having a generally uniform thickness. The top plate <NUM> may be manufactured from other materials and processes; for instance, the top plate <NUM> can be molded from a polymeric material. In addition, while the top plates <NUM> are shown as uniform modular components, it is appreciated that top plates of varying forms may be used when beneficial for a particular application.

The example top plate <NUM> defines a generally planar transport surface <NUM> that includes an array of perforations <NUM>, which can allow for drainage and airflow through the transport surface <NUM>. The transport surfaces <NUM> of a plurality of top plates <NUM> can combine to collectively define the conveying surface <NUM>. The perforations <NUM> can take on a variety of orientations, sizes, and form factors (see, for instance, <FIG>), or be absent (shown, for example, in <FIG>) such that the transport surface <NUM> is generally continuous. In addition, in other embodiments, the transport surface <NUM> can provide a textured or contoured surface that may improve frictional engagement and/or positive structural engagement between the transport surface <NUM> and a particular product to be conveyed. The top plates <NUM> can further include or define application-specific structures (e.g., resilient fingers, dividers, fights, etc.).

The example top plate <NUM> engages the underlying picket <NUM> near a leading end <NUM> at the leading interface and near a trailing end <NUM> at the trailing interface. The leading end <NUM> also includes structures to engage a cross-rod <NUM> used to pivotally interconnect adjacent rows of pickets <NUM>. The generally rectangular transport surface <NUM> of the top plate <NUM> is formed with downwardly extending side skirts <NUM>, and includes a pair of arms <NUM> near the leading end <NUM> and an arcuate tail <NUM> near the trailing end <NUM>. The arms <NUM> angle downward from the transport surface <NUM> at a curved portion <NUM> to a lower portion <NUM>, such that the lower portion <NUM> is skewed relative to the transport surface <NUM>. A tab <NUM> is formed at an orientation that generally extends orthogonally to the lower portion <NUM> in a direction toward the trailing end <NUM> and generally parallel with the side skirts <NUM>. Each lower portion <NUM> of the respective tab <NUM> includes an outer side <NUM> that skews laterally inward toward the centerline C of the top plate <NUM> (illustrated in <FIG>). Each tab <NUM> includes an opening <NUM> and an ear <NUM>, which includes an arcuate upper end <NUM> that extends away from a centerline C of the top plate <NUM>. As with the openings <NUM>, the ears <NUM> can comprise a variety of form factors (e.g., protrusions, recesses, inserts, etc.) that are configured to mate and interface with the form factor defined by the picket leading interface portion (e.g., the example openings <NUM>). The openings <NUM> are somewhat elongated and are sized and positioned to accommodate the cross-rod <NUM> during use; therefore, in the example embodiment, the top plates <NUM> are engaged with the pickets <NUM> prior to inserting the cross-rods <NUM> to interconnect adjacent rows of top plates <NUM> and supporting pickets <NUM>.

The tail <NUM> near the trailing end <NUM> curves downward and away from the transport surface <NUM>, ultimately curving back toward the leading end <NUM> of the top plate <NUM> at a trailing edge <NUM> to define generally horizontal lip <NUM>. As best illustrated in <FIG>, the example tail <NUM> includes sides <NUM> that skew inward towards the centerline C of the top plate <NUM>. In the example top plate <NUM>, a pair of laterally spaced tabs <NUM> extend from the lip <NUM> toward the leading end <NUM>. Each tab <NUM> slightly tappers toward a tip <NUM>, and the tabs <NUM> comprise a portion of the example top plate trailing interface portion of the trailing interface between the picket <NUM> and the top plate <NUM>. The tabs <NUM> can take on a variety of form factors (e.g., openings, slots, grooves, protrusions, nibs, inserts, etc.), provided the top plate trailing interface portion and the picket trailing interface portion are adapted to interact at the trailing interface between the picket <NUM> and the top plate <NUM> to interface the top plate <NUM> and the picket <NUM>.

With specific reference to <FIG>, the form factor of the top plate <NUM> includes features that generally maintain a desired spacing and orientation between adjacent top plates <NUM> during use. The curved portion <NUM> defines an arcuate segment <NUM> that has a leading radius of curvature LR extending from a leading pivot axis LP, and the tail <NUM> defines another accurate segment <NUM> that has a trialing radius of curvature TR extending from a trailing pivot axis TP. The curvature of these segments <NUM>, <NUM> (relative to the leading and trailing pivot axes generally defined by the orientation of the leading and trailing cross-rods <NUM>) maintains a nearly constant spacing between adjacent top plates <NUM> as they traverse and pivot about the leading pivot axes LP and the trailing pivot axes TP. In addition, these features maintain a consistent and relatively smooth transition between adjacent top plates <NUM>.

The example interface and engagement between the picket <NUM> and top plate <NUM> is described with additional reference to <FIG>. The example picket <NUM> and the example top plate <NUM> are configured to interface at a leading interface and at a trailing interface (annotated in <FIG> as LI and TI, respectively). Specifically, the leading interface includes a picket leading portion and a top plate leading portion that are both adapted to establish cooperating form factors that mate the picket <NUM> and the top plate <NUM> near leading ends. As shown in the example configuration, the picket <NUM> includes an example picket leading portion defining openings <NUM> that establish a form factor adapted to interface with an example top plate leading portion of the top plate <NUM> defining ears <NUM>. In addition or alternatively, the example leading interface can include the cooperation between the openings <NUM> of the picket <NUM>, the openings <NUM> in the top plate <NUM>, and the assembly of the cross-rod <NUM> through the openings <NUM>, <NUM>. Similarly, the trailing interface includes a picket trailing portion and a top plate trailing portion that are both adapted to establish cooperating form factors that mate the picket <NUM> and the top plate <NUM> near trailing ends. As shown in the example configuration, the picket <NUM> includes an example picket trailing portion defining slots <NUM> that establish a form factor adapted to interface with an example top plate trailing portion of the top plate <NUM> defining tabs <NUM>. Given the benefit of this disclosure, one of ordinary skill in the art will appreciate the various structures and form factors that can be employed to implement the interface concepts that can inhibit separation of top plates from pickets.

To mate the example top plate <NUM> with the example picket <NUM>, the top plate <NUM> is generally aligned as shown in <FIG> (as annotated by engagement lines). The tabs <NUM> on the trailing end <NUM> of the top plate <NUM> are aligned for insertion into the slots <NUM> formed in the trailing end portions <NUM> of the trailing link <NUM>. The tapered form factor of the tabs <NUM> can be configured to securely engage a receiving form factor defined by the structure of the slots <NUM>. Turning to the leading end <NUM> of the top plate <NUM>, the opening <NUM> in one tab <NUM> is generally aligned with the opening <NUM> formed near the leg portion <NUM> of the edge link <NUM>, and the other opening <NUM> of the other tab <NUM> is generally aligned with the opening <NUM> formed near the leg portion <NUM> of the leading link <NUM>. Similarly, the ear <NUM> of one tab <NUM> is generally aligned with the opening <NUM> formed in the leg portion <NUM> of the edge link <NUM>, and the other ear <NUM> of the other tab <NUM> is generally aligned with the opening <NUM> formed in the leg portion <NUM> of the leading link <NUM>. The contour of the ears <NUM> and the respective upper ends <NUM> are inserted by slight elastic deformation of, for instance, one or more of the picket <NUM>, the ear <NUM>, and the tab <NUM>. Once engaged, the upper ends <NUM> of the ears <NUM> interfere with the boundary of the opening <NUM> to inhibit unintentional removal of the top plate <NUM>, and can abate noise caused by excess relative movement of the top plate <NUM>. In addition, the interaction between and relative placement of the ears <NUM> and the corresponding openings <NUM> establish positioning features that aid assembly of the top plates <NUM> to the pickets <NUM> by, for example, aligning the openings <NUM> in the picket <NUM> with the openings <NUM> in the top plate <NUM> (discussed below) to readily receive the cross-rod <NUM>.

When the top plate <NUM> of <FIG> is installed, the top plate <NUM> extends between and generally covers the edge link <NUM>, the laterally adjacent trailing link <NUM>, and approximately half of the laterally adjacent leading link <NUM> (best illustrated in <FIG> and <FIG>). With specific reference to <FIG> and <FIG>, another top plate <NUM> can be similarly assembled by again aligning the interconnecting interface features of the picket <NUM> and the additional top plate <NUM>.

With the desired top plates <NUM> secured to the appropriate pickets <NUM>, the cross-rods <NUM> can be aligned with the respective openings <NUM>, <NUM> in the edge links <NUM>, leading links <NUM>, and trailing links <NUM> of the pickets <NUM>, and openings <NUM> in the tabs <NUM> of the top plates <NUM>. In other embodiments, the pickets <NUM> and top plates <NUM> can be modified such that the top plate <NUM> is secured to the pickets <NUM> by tabs <NUM> on the trailing end <NUM> and by similar tabs on the leading end <NUM>. For instance, tabs on the leading end <NUM> may extend from the lower portion <NUM> of the top plate <NUM> and extend into the slots <NUM> formed in the edge link <NUM> and the leading links <NUM>.

A portion of the flatwire conveyor belt <NUM> illustrating four rows <NUM> is further shown in <FIG>, and various additional features of the pickets <NUM> and the top plates <NUM> are illustrated. In one embodiment, the top plates <NUM> are sized to provide a lateral space or gap <NUM> between laterally adjacent top plates <NUM>. This provides, for instance, space to accommodate lateral compression of the underlying pickets <NUM> that can occur during assembly of the flatwire conveyor belt <NUM>. The gap <NUM>, however, can be sized to reduce the potential for products being conveyed to undesirably interact with the gap <NUM>. Where a relatively smooth, continuous conveying surface <NUM> is desired, the notches <NUM> formed in the edge end portions <NUM> of each edge link <NUM>, the leading end portion <NUM> of the leading link <NUM>, and the trailing end portion <NUM> of the trailing link <NUM> can accommodate a respective top plate <NUM>, such that the top plate <NUM> is seated in preferred orientation relative to other top plates <NUM> and may be positioned generally directly on the picket <NUM>.

In addition, several contours and form factors of the pickets <NUM> and the top plates <NUM> enhance hinging of the adjacent rows <NUM>. For instance, the contours of the arms <NUM> at the leading end <NUM> and the tail <NUM> at the trailing end <NUM> can be configured to establish desired clearance for uninhibited rotation within a practical range of operation of the flatwire conveyor belt <NUM>.

In the example embodiment, each row <NUM> is generally identical and comprised of pickets <NUM> and top plates <NUM> of substantially similar form factors, respectively. In addition, the picket <NUM> and the top plate <NUM> include various contours provided to enhance manufacturability from strip/sheet material using, for instance, die cutting, stamping, and press forming processes. Depending on the form factor and envelope constraints for a particular flatwire conveyor belt application, the spacing and construction of the picket and top plate can be adapted accordingly. For example, top plates of varying form factor can be provide to establish a brick-lay pattern having offset top plate placement between adjacent rows, such that successive rows do not combine to establish continuous gaps or contours. In one example, a combination of top plates of discrete lateral dimensions (e.g., <NUM> inches in lateral width and <NUM> inches in lateral width) can be configured to establish a brick-lay pattern.

An alternative embodiment of an example portion of flatwire conveyor belt <NUM> is illustrated in <FIG> and <FIG>. While many similarities to the flatwire conveyor belt <NUM> are present, a difference exists in that a picket <NUM> has been modified to accommodate and restrain a portion of a guide system. For example, the guide system, such as the Positrack system employed by Rexnord Corporation of Milwaukee, Wisconsin, can include a track or rail (not shown). The flatwire conveyor belt <NUM> includes a mating positioning element <NUM> that is configured to interact with the track or rail during operation of the flatwire conveyor belt <NUM>. The example positioning element <NUM> includes various surfaces, such as lateral sides <NUM>, which can be configured to ride along or engage with portions of the track or rail to direct, limit, or at least partially restrain undesired movement of the flatwire conveyor belt <NUM>.

With additional reference to <FIG> and <FIG>, the form factor of the example picket <NUM> is similar to picket <NUM>. Picket <NUM> includes a series of openings <NUM> that are formed through select ones of the side bars <NUM>. While the axis of each opening <NUM> is generally aligned, in one embodiment, the openings <NUM> formed in the respective side bar <NUM> of the end links <NUM> may be positioned slightly above the openings <NUM> formed in the remaining side bars <NUM> (shown best in <FIG>). With specific reference to <FIG> and <FIG>, the picket <NUM> differs in that at least side bar <NUM> does not include any opening (i.e., similar to openings <NUM>). Therefore, the example positioning element <NUM> can be seated between trailing links <NUM> and a guide rod <NUM>, which is sized accordingly, can be inserted into the openings <NUM>, through cylindrical channel or openings <NUM> in or through the positioning element <NUM>, and generally abutted against side bar <NUM>. This construction effectively captures the positioning element <NUM> with the picket <NUM>. To inhibit the guide rod <NUM> from undesirable removal, a rivet <NUM> (or other structure, such as a plug, a clip, etc.) can be used to block at least a portion of the outermost opening <NUM> formed in the edge link <NUM>.

An alternative top plate <NUM> is illustrated in <FIG> and <FIG>. While the top plate <NUM> is similar to the top plate <NUM>, various differences are shown. The top plate <NUM> includes leading arms <NUM>, <NUM> that extend from a main body <NUM> in a leading direction, and a single trailing tail <NUM> that extends from the main body <NUM> in a trailing direction. The main body <NUM> includes a generally continuous, planar transport surface <NUM>. Similar to the top plate <NUM>, the tail <NUM> curves downward from the main body <NUM> and terminates in a pair of laterally spaced tabs <NUM>. The tabs <NUM> are configured to interface with mating slots formed in a supporting picket (e.g., slots <NUM> formed in the trailing end portion <NUM> of the picket <NUM> shown in <FIG>). The tail <NUM> further includes a series of openings <NUM> formed along a trailing end <NUM>.

The leading end of the top plate <NUM> differs somewhat from the top plate <NUM>. Each arm <NUM>, <NUM> includes a curved portion <NUM> that extends from the main body <NUM> and downward to terminate in a leading tab <NUM>. The leading tabs <NUM> are generally rectangular in form factor and extend from distal ends of the arms <NUM>, <NUM> toward the tail <NUM>. The leading tabs <NUM> are configured to engage mating slots formed in the leading end portion of a picket, such as the slots <NUM> formed in the leading end portion <NUM> of the picket <NUM> (show in <FIG>). The arms <NUM>, <NUM> also include a series of openings <NUM> formed along a leading end <NUM>.

The alternative top plate <NUM> engages the underlying picket (e.g., picket <NUM>) at a leading interface and at a trailing interface. In particular, the tabs <NUM> of the tail <NUM> are engaged with respective slots <NUM> formed in the trailing end portion <NUM> of the picket <NUM>, and the leading tabs <NUM> are engaged with respective slots <NUM> formed in the leading end portion <NUM> of the picket <NUM>. The top plate <NUM> and/or the picket (e.g., picket <NUM>) may be elastically deformed or flexed to allow the top plate <NUM> to be aligned and releasably engaged with the underlying picket <NUM>. Given the benefit of this disclosure, one skilled in the art will appreciate the various interface form factors available to implement the fundamental concepts.

Another alternative top plate <NUM> is illustrated in <FIG>. The top plate <NUM> defines a main body <NUM> with an array of perforations <NUM> that extend through the main body <NUM> between a transport surface and an underside. Each perforation <NUM> is generally cylindrical and the array of perforations <NUM> is generally mirrored about line L. In other embodiments, perforations may be non-uniform, both in individual form factor and/or in relative position on the top plate <NUM>. One skilled in the art will understand the various alternatives that fall within the purview of the disclosed concepts.

<FIG> illustrates another flatwire conveyor belt <NUM> in accordance with one example embodiment. The flatwire conveyor belt <NUM> is similar to the flatwire conveyor belt <NUM> described above and is typically an endless belt driven in a direction of travel (designated by arrow D), and constructed to address particular application requirements. Each row <NUM> includes a picket <NUM> that supports multiple modular top plates <NUM>. Adjacent rows <NUM> are interconnected by a first set of cross-rods <NUM> that extends laterally (relative to the direction of travel D) through the pickets <NUM>, generally forming a hinge connection. A second set of cross-rods <NUM> also extends laterally through the pickets <NUM>. As shown, the first set of cross-rods <NUM> and the second set of cross-rods <NUM> are provided in an alternating pattern; however, fewer of the second set of cross-rods <NUM> can be provided depending on the application-specific requirements.

In use, the first set of cross-rods <NUM> is typically engaged by one or more sprockets driven by a motor that rotates the sprocket(s) to engage and drive against the first set of cross-rods <NUM> from beneath the flatwire conveyor belt <NUM>. The second set of cross-rods <NUM> extends through and supports rollers <NUM>. Each of the rollers <NUM> can rotate about a respective cross-rod of the second set of cross-rods <NUM> freely and independently from each other, the pickets <NUM>, and the modular top plates <NUM>. In other forms, some or all of the rollers <NUM> may be rotatably secured to the cross-rods <NUM> such that the rollers <NUM> and cross-rods <NUM> rotate in unison. It is contemplated that there may be greater or fewer rollers <NUM> per picket <NUM> (or per flatwire conveyor belt <NUM>) than shown in <FIG>, as adjustments can be made depending on the application-specific requirements (e.g., load-carrying capacity requirements). The example rollers <NUM> are generally cylindrical with a central axial opening though which the cross-rods <NUM> extend. In alternative embodiments, the rollers <NUM> may take other form factors, such as tapered, arcuate, convex, concave, and the like. The rollers <NUM> can be constructed of, for instance, a variety of plastic and/or metallic materials, and may include an internal bushing, bearing, and the like within the central axial opening to influence the relative engagement with the cross-rods <NUM> (e.g., reduce sliding friction).

In the example shown, both the first and second sets of cross-rods <NUM>, <NUM> are metallic with ends <NUM>, <NUM> that are formed or mushroomed to limit lateral movement (i.e., in a direction generally skewed to the direction of travel D) of the cross-rods <NUM>, <NUM> once adjacent rows <NUM> are interconnected. In alternative embodiments, other restraint mechanisms can be used to restrain the cross-rods, such as collars or clips, and the cross-rods can be constructed of non-metallic materials (e.g., plastics or composites). One alternative example construction is shown in <FIG> in which the cross-rod <NUM> takes the form of an axle <NUM> that is captured in a row <NUM>. Specifically, a modified picket <NUM> of the row <NUM> differs as the outermost side bar <NUM> does not include an opening aligned with the assembled axle <NUM>. Thus, the axle <NUM> can be inserted through generally aligned openings <NUM> in the picket <NUM> until the axle <NUM> abuts the outermost side bar <NUM>. The opening <NUM> formed in the opposite outermost side bar <NUM> can be blocked by a rivet <NUM> (or other structure, such as a plug, a clip, etc.) to inhibit the axle <NUM> from excessive lateral movement. In this embodiment, the axle <NUM> is generally free-floating, such that the axle <NUM> is able to rotate and shift laterally, while being ultimately restrained by the outermost side bar <NUM>, the openings <NUM>, and the rivet <NUM>.

As shown in <FIG>, the example second set of cross-rods <NUM> (or axle <NUM>) can be spaced from the modular top plates <NUM> so that the second set of cross-rods <NUM> is lower in the pickets <NUM> in relation to the first set of cross-rods <NUM>. As shown, a first dimension A between the center axis of the second set of cross-rods <NUM> and the top surface of the flatwire conveyor belt <NUM> is greater than a second dimension B between the center axis of the second set of cross-rods <NUM> and the bottom surface of the flatwire conveyor belt <NUM>. This defines a gap <NUM> between the top of the rollers <NUM> and the modular top plates <NUM>, thereby allowing the rollers <NUM> to extend below the pickets <NUM> but not interfere with the modular top plates <NUM>. The relationship between the first dimension A and the second dimension B is generally constrained by the first dimension A avoiding interference between the rollers <NUM> and the modular top plates <NUM>, and the second dimension B accommodating sufficient material of the picket <NUM> to achieve the particular application requirements (e.g., fatigue strength, load-carrying capacity, etc.). In one particular embodiment, the rollers <NUM> can be configured to extend beyond the bottom surface approximately <NUM>/<NUM>" to <NUM>/<NUM>", with a correspondingly sized gap <NUM>.

Claim 1:
A module capable of use in a flatwire conveyor belt assembly, the module comprising:
a picket (<NUM>) having leading links (<NUM>) and trailing links (<NUM>), the picket (<NUM>) defining a picket (<NUM>) leading portion proximate the leading links (<NUM>) and a picket (<NUM>) trailing portion proximate the trailing links (<NUM>);
a top plate (<NUM>) having a leading end (<NUM>) and a trailing end (<NUM>), the top plate (<NUM>) defining a top plate leading portion proximate the leading end (<NUM>) and a top plate trailing portion proximate the trailing end (<NUM>);
wherein the picket (<NUM>) and the top plate interface at a leading interface defined by an interface of the picket (<NUM>) leading portion and the top plate leading portion; and
wherein the picket (<NUM>) and the top plate (<NUM>) interface at a trailing interface defined by an interface of the picket (<NUM>) trailing portion and the top plate (<NUM>) trailing portion,
characterized in that:
the picket (<NUM>) trailing portion comprises a slot (<NUM>);
the top plate trailing portion comprises a tab (<NUM>); and
the slot (<NUM>) and the tab (<NUM>) are configured to interface when the top plate (<NUM>) is positioned atop the picket (<NUM>).