Patent Description:
Conveyor belts are popularly used in a number of different industrial fields to provide continuous motion of goods during manufacture, shipping, and other processes. Industrial conveyor belts generally include a series of spaced apart rods connected via a series of links, which are welded or otherwise coupled to the rods. Such belts are commonly referred to as modular conveyor belts.

For the manufacture of small items, the rods may be covered with a fabric, plastic, or metal overlay, such as a mesh, to prevent the small items from slipping between the rods and falling to the manufacturing floor. Further, the structure of the links that make up modular conveyor belts varies.

Generally, conveyor belts and links are formed of either metal or plastic. Metal conveyor belt links typically have excellent strength properties, but exhibit wear at surfaces where the links contact the rods. On the other hand, plastic conveyor belt links are typically resistant to wear at contact surfaces, but are sometimes less strong than metal belts commonly resulting in failure due to fatigue and/or excess loading.

Generally, although metal and plastic belts typically differ as to the mode of failure, comparable metal and plastic belts commonly have similar longevity. That is, metal belts commonly last as long as a plastic belt configured for similar duty, however, the plastic belt will typically fail due to fatigue or an instantaneous load spike, whereas the metal belt will fail due to wear. For similarly structured plastic and metal links, a metal link may have a tensile strength that is <NUM>-<NUM> times that of a comparable plastic link. In addition, different portions of a turn curve conveyor belt are loaded differently, such that a material that may be well-suited for a given portion of a conveyor belt may be less well-suited for other portions of the conveyor belt. Further relevant prior art is described in <CIT>, <CIT>, <CIT>, <NPL>, <CIT>, <CIT>, <CIT>, <CIT> and <CIT>. <CIT> discloses a modular conveyor belt, comprising a first link and a second link and an elongated connecting rod <NUM> configured to hingedly attach the first link and the second link to one another. The first link includes a structure formed of a first material and another structure formed of a second material covering at least a portion of the first structure. The second structure prevents the first structure from contacting a driving drum of the modular conveyor belt. The first link has a substantially U-shaped configuration formed by two substantially longitudinally oriented legs each having rod apertures at forward and trailing ends and a laterally oriented cross-member between the two legs.

These and other problems exist with respect to conveyor belts and/or conveyor belt links.

In particular, the present invention provides a modular conveyor belt having the features defined in Claim <NUM>. Further preferred arrangements are defined in the dependent claims. arrangements.

In the following, there are described some arrangements. However, the scope of protection is defined by the claims. In the following arrangements, in particular, the arrangements shown in <FIG>, <FIG> and <FIG> are arrangements of the present invention. In particular, the bearing structure is configured to prevent contact between the rod and the supporting structure at the apertures at the forward and the trailing ends and a portion of the bearing structure is disposed such that, when a conveyor belt connecting rod is positioned through the apertures at the forward ends of the legs of the first link, the bearing structure is located at a rod contacting surface of the cross-member. The further arrangements are helpful for understanding the present invention.

The present disclosure describes systems and methods for providing modular conveyor belt links with both wear resistance and strength.

Examples of basic conveyor belt structures and manufacturing methods can be found in <CIT>. The accompanying <FIG> corresponds to <FIG> of the '<NUM> patent, and illustrates a typical prior art modular conveyor belt <NUM>. Conveyor belt <NUM> includes rods <NUM> connected by links <NUM> and covered by a mesh <NUM> to provide additional support for the goods transported on conveyor belt <NUM>.

In some cases, a buttonhead <NUM> may be formed on the ends of rods <NUM> to act as a stop for links <NUM>. A weld is also typically formed between buttonhead <NUM> and link <NUM> for a stronger and more secure connection between rods <NUM> and links <NUM>. In other cases, a buttonless configuration may be employed, wherein the rod is welded to the link without creating a significant protrusion beyond the leg of the link.

<FIG> shows an enlarged view of a portion of prior art conveyor belt <NUM>, showing rods <NUM> formed with buttonheads <NUM>. In addition, <FIG> also shows a weld <NUM> fastening buttonhead <NUM> and, therefore, rod <NUM>, to link <NUM>.

The term "conveyor belt," as used in the present disclosure, generally refers to any type of endless track or belt, typically configured to be driven by a geared mechanism or drum. The term "conveyor belt" should not be considered to be limited to any particular type of conveyor belt unless otherwise specified herein.

The directional term "lateral" or "laterally," as used in the present disclosure, refers to an outwardly direction relative to the centerline of the entire conveyor belt.

The term "longitudinal" as used in the present disclosure and claims refers to a direction in which the conveyor belt travels. Further the term longitudinal refers to both forward and backward directions of conveyor belt travel.

The term "vertical," as used in the present disclosure and claims refers to the up and down direction relative to the ground.

The conveyor belt systems, and methods of building such systems, as described herein, may include different types of conveyor belts. In some arrangements, the conveyor belts may be modular conveyor belts. Modular belts may be formed of intermeshing modules, disposed in laterally extending rows, that are rotatably joined longitudinally. In some cases, a row of a modular belt may include multiple modules disposed laterally, and joined, for example, by a connecting rod. Modular belt modules may include laterally-aligned rod holes or slots at the forward and rearward portions of each row.

The term "link," as used in the present disclosure and claims, refers to a basic component of a conveyor belt row. For example, one individual link may be repeated laterally in order to form an entire row of links. In some arrangements, only two links per row are provided (at each end of the rod). In some arrangements, the links are capable of rotating independently from one another. In some arrangements, two or more links may be rigidly attached to one another.

The term "rod" or "connecting rod" refers herein to an elongated member used to associate links together. When associated, the links and rod form a basic modular conveyor belt.

The term "pitch" refers herein to one row of links extending from one lateral edge of the conveyor belt to the opposite lateral edge. In some arrangements, the pitch may be formed of one piece so that all the links in the same row are rigidly attached to one another. In other arrangements, the pitch may have multiple individual links arranged side-to-side, allowing each individual link to rotate with respect to one another. In other arrangements, the pitch may include a minimal number of links, such as only end links connected by connecting rods. In some arrangements, the pitch may include not only end links, but also one or more spaced-apart intermediate links positioned between the end links along the connecting rod.

The term "end link" refers herein to the most laterally disposed link in the pitch, or the terminating link for the pitch in a row. In some arrangements each pitch may have two end links, one end link for each side of the conveyor belt.

The term "retention cage" refers herein to a structure that is associated with the end link such that the retention cage is located on the side of the end link that is outward from the centerline of the conveyor belt. In other words, the retention cage forms the edge of the conveyor belt. In some arrangements, the retention cage secures the connecting rod so that the rod is not inadvertently removed from the conveyor belt during operation, assembly, or any other time.

<FIG> shows a top view of an exemplary modular conveyor belt <NUM>. As illustrated in <FIG>, conveyor belt <NUM> may include a plurality of links <NUM> connected by a plurality of elongated rods <NUM>. A center line <NUM> indicates the approximate midline of conveyor belt <NUM>. Conveyor belt <NUM> may include outer ends <NUM>. For purposes of this disclosure, the term "outer," as used in this description and the appended claims, shall refer to a direction toward outer ends <NUM> of conveyor belt <NUM> and away from center line <NUM>. Conversely, the term "inner" shall refer to a direction toward center line <NUM> and away from outer ends <NUM> of conveyor belt <NUM>. In addition, for purposes of this disclosure, the term "longitudinal direction" shall refer to the direction in which center line <NUM> is oriented.

As shown in <FIG>, all of rods <NUM> may be substantially similar in shape and dimension, with each of rods <NUM> being an elongated cylindrical body formed of an elongated portion of a rod material. In some arrangements, rods <NUM> may be made from a metal material, such as steel, stainless steel, aluminum, titanium, and/or other metals. In other arrangements, rods <NUM> may be made from a non-metallic material, such as plastic, wood, carbon fiber, and/or other non-metallic materials. In some arrangements, rod <NUM> may be a substantially hollow tube or pipe. In other arrangements, rod <NUM> may be solid.

The inner portions of rods <NUM> (near center line <NUM>) are truncated in <FIG> for purposes of illustration. Rods <NUM> may be any suitable length for supporting and carrying a variety of wares. In some arrangements, rods <NUM> may have a uniform or substantially uniform diameter along the length of the cylindrical body. The diameter may be selected based upon factors such as the type of goods being moved on conveyor belt <NUM>, the width of conveyor belt <NUM>, and/or other considerations. In some arrangements, rods <NUM> may include tapering or stepped configurations.

As shown in <FIG>, rods <NUM> may be operatively connected to each other with links <NUM>. In some arrangements, links <NUM> may be substantially U-shaped, wherein each link <NUM> is constructed with two legs, including an inner leg <NUM> and an outer leg <NUM>, joined by a connecting member <NUM>. In some arrangements, inner leg <NUM> and outer leg <NUM> may be mirror-image forms. Accordingly, as the configuration of inner leg <NUM> and outer leg <NUM> are identical save for opposing orientation, for the sake of clarity, only the structure of outer leg <NUM> is discussed with particularity. Outer leg <NUM> may include a relatively straight upper portion <NUM> connected by an outwardly-tapering transition region <NUM> to a relatively straight lower portion <NUM>. This configuration creates a wider lower opening <NUM> to allow for the interconnection of links <NUM>, as connecting member <NUM> of one link may readily slide into a nesting relationship with lower portion <NUM> of an adjacent link. In some arrangements, the fitment of one link within another may be a relatively loose fitment, allowing several millimeters of lateral movement between the components. In other arrangements, the fitment may be substantially tighter, leaving only minimal space between the components, and thus, maintaining the links in a consistent alignment when nested.

It will be appreciated that the form of the links joining together elongate rods is not limited to the configurations shown and discussed in the present disclosure. In some arrangements, the configuration of the connective links may be simpler than link <NUM>. For example, in some arrangements, each leg of the link may include a single straight portion. Alternatively, the configuration of the connective link may be more involved for certain applications. For example, arrangements are envisioned wherein the connective links have more bends and/or a more complex shape than link <NUM>. In addition, although inner leg <NUM> and outer leg <NUM> are shown in the accompanying drawings as having mirror images of each other to provide symmetry for link <NUM>, in other arrangements, link <NUM> may be asymmetrical.

Each rod <NUM> may be fixedly attached to two links <NUM> (for example by welding), one at each end of the rod, forming a pitch <NUM>. Pitches <NUM> may be rotatably connected to one another. For example, each rod <NUM> may pass through openings <NUM> in upper portions <NUM> of outer legs <NUM> and through corresponding openings in inner legs <NUM>. While rods <NUM> may be fixedly attached to outer leg <NUM> at or near opening <NUM> in lower portion <NUM>, rods <NUM> may be free to rotate within the openings <NUM> in upper portions <NUM> and the counterpart openings in inner legs <NUM>.

In some cases, conveyor belts may be configured for a straight path of conveyance. Such belts are often referred to as "straight run" conveyor belts. In other cases, conveyor belts may be configured for turning laterally to the left and/or right. Such belts are often referred to as "turn curve" conveyor belts. In order to navigate curves, modular conveyor belts may be collapsible longitudinally. In some cases, the entire width of the belt may be collapsible longitudinally. In other cases, only one end of the belt may be collapsible, for example, when the belt is only needed to turn in one direction. Belts may be made collapsible by utilizing longitudinally oriented slots instead of circular holes to receive the rods. The structure that enables collapsibility of conveyor belts is discussed in greater detail below.

Conveyor belt <NUM>, as shown in <FIG>, may be a collapsible type of conveyor belt. That is, the belt pitches may be movable longitudinally with respect to one another. In order to facilitate this longitudinal collapsibility, the openings <NUM> in upper portions <NUM> of outer legs <NUM> and counterpart openings in inner legs <NUM> may be longitudinally slotted, as shown in <FIG>, thus allowing for longitudinal translation of a rod of a given pitch <NUM> within a link of an adjoining pitch.

Conveyor belt <NUM> may be collapsible at both outer ends <NUM> or at only one of outer ends <NUM>. Further, in some arrangements, outer ends <NUM> may be independently collapsible, that is, each end <NUM> may be collapsible independent of the opposite outer end <NUM> of conveyor belt <NUM>. This independent collapsibility may enable conveyor belt <NUM> to be propelled around turns. That is, when being propelled around a turn, the outer end <NUM> of conveyor belt <NUM> that is on the inside of the turn may collapse longitudinally, whereas the outer end <NUM> on the outside of the turn may remain expanded longitudinally. Such a conveyor belt may be referred to as a "turn-curve" conveyor belt.

Conveyor belt <NUM> may be driven, pulled, propelled, and/or guided by a structure such as a drum <NUM>. Drum <NUM> may have a drive surface <NUM>, which may contact outer end <NUM> of conveyor belt <NUM>. In some arrangements, drum <NUM> may be configured to simply guide conveyor belt <NUM> along a designated path. That is, a separate drive mechanism may propel conveyor belt <NUM>, and drum <NUM> may guide conveyor belt <NUM> along the designated path. In other arrangements, drum <NUM>, in addition to guiding conveyor belt <NUM>, may also be configured to propel conveyor belt <NUM>. Thus, conveyor belt <NUM> may be configured to contact drive surface <NUM>.

The drive surface of the drum or other such propulsion or guidance device may be configured to engage a conveyor belt. The drive surface may be made of any suitable material for such contact. For example, the drive surface of the drum may be made of rubber, plastic, metal, and other suitable materials. These materials can be hard, abrasive, and/or may carry debris that acts as an abrasive during contact of the drive surface with the contact weld on an outer portion of the conveyor belt.

In some cases, conveyor belts may be flat top belts. Flat top belts are manufactured with a support surface on one face of the links so that the surface abuts an adjacent link, therefore leaving no significant open areas between rows, or pitches.

In some arrangements, the belts may be picket style belts. Picket style belts have transverse links resembling the shape of a square wave mathematical function. The links in picket style belts have laterally aligned rod holes or slots allowing for a connecting rod to be inserted.

In some cases, the pickets or "pitches" of picket style belts may have the formed of an oscillating flat member. Such picket style belts are referred to as "flat wire" style belts. Examples of basic flat wire style conveyor belt structures and manufacturing methods can be found in <CIT> and <CIT>. These structures and methods of manufacturing are generally applicable to the conveyor belt arrangements described herein.

<FIG> is a schematic view of two pitches of a prior art flat wire style conveyor belt <NUM>. As can be seen in <FIG>, flat wire belt <NUM> may include a first pitch <NUM>, which may have multiple rod receiving apertures <NUM>. Belt <NUM> may also include a second pitch <NUM>. Second pitch <NUM> may also include multiple rod receiving apertures <NUM>. When rod receiving apertures <NUM> are aligned with rod receiving apertures <NUM>, a substantially straight rod receiving path, configured to receive a connecting rod <NUM>, is formed extending transversely across second pitch <NUM>.

In order to assemble a conveyor belt using first pitch <NUM> and second pitch <NUM>, first pitch <NUM> may be positioned adjacent to a second pitch <NUM>. First pitch <NUM> is then engaged with or interconnected with second pitch <NUM> so that first pitch rod receiving apertures <NUM> align with second pitch rod receiving apertures <NUM> to form a rod receiving path. The rod receiving path enables connecting rod <NUM> to be pushed through both first pitch rod receiving apertures <NUM> and second pitch rod receiving apertures <NUM> to associate first pitch <NUM> and second pitch <NUM>.

Another type of conveyor belt is a finger style belt. Finger style belts may include links that feature a straight or zig-zag central transverse rib from which finger-like protrusions extend in the forward and/or rearward direction. The fingers typically have laterally aligned rod holes or slots allowing for a connection rod to be inserted.

<FIG> illustrates an exemplary finger style belt <NUM>. As shown in <FIG>, belt <NUM> may include a first pitch <NUM> hingedly connected to a second pitch <NUM> via a connecting rod <NUM>. Each pitch of belt <NUM> may include a zig-zag transverse rib <NUM>. In addition, each pitch may include alternating finger-like protrusions <NUM>, which may include rod receiving apertures <NUM> configured to receive connecting rod <NUM>.

In some arrangements, links of conveyor belt pitches may include rod retention features configured to prevent undesired removal of connecting rods from assembled conveyor belts. In some arrangements, end links on both right and left lateral edges of the conveyor belt may include rod retaining features. In other arrangements, only selected end links may be provided with rod retaining features. For example, in some arrangements, only right end links or only left end links may be provided with rod retaining features. In some arrangements, all pitches of the belt may have the rod retaining feature on the same edge. In other arrangements, pitches in the belt may alternate as to which edge of the belt, right or left, includes the retention feature. For example, a first pitch may have an end link on the right edge of the belt that includes a rod retention feature, and a second, adjacent pitch may have an end link on the left edge with a rod retention feature, and a third pitch, adjacent the second pitch, may include an end link on the right edge with a rod retention feature, and so on.

<FIG> illustrates a conveyor belt <NUM> including rods <NUM> and links <NUM> connected to rods <NUM>. Links <NUM> generally have a substantially U-shaped configuration formed by two substantially longitudinally oriented legs <NUM>, tapered sections <NUM>, and a laterally oriented cross-member <NUM> between the two legs <NUM>. Legs <NUM> may include an aperture, such as an elongated aperture, that receives rod <NUM> and associates links <NUM> with rods <NUM>.

Legs <NUM> of links <NUM> are spaced apart in order to receive the cross-member <NUM> of an adjacent link. For example, legs <NUM> of the link 210b are suitably spaced apart to receive cross-member <NUM> of the link 210a when conveyor belt <NUM> is in motion. During motion, link 210a may contact link <NUM>0b at various contact points, including at points on cross-members <NUM>, on legs <NUM>, and so on.

In some arrangements, links <NUM> may include provisions for reducing wear of links <NUM>. One way to reduce wear of the links is to select wear resistant materials for the link. However, in some cases, suitable wear resistant materials may lack the tensile strength desired for the links. In contrast, materials with suitable tensile strength often lack the desired wear resistance. Accordingly, in some arrangements, links <NUM> may be composite links, formed of a supporting structure and a bearing structure. The supporting structure may have a tensile strength that is higher than the tensile strength of the bearing structure, and the bearing structure may be more resistant to wear than the supporting structure.

The configuration of this composite link structure may vary to achieve desired performance characteristics. In some arrangements, the bearing structure may partially enclose or cover the supporting structure. For example, in some cases, the bearing structure may be provided only in areas of the link that are subject to contact with other components of the conveyor belt, such as connecting rods, other links, stationary components of the conveyor frame, and/or moving components of the conveyor drive mechanism. In other arrangements, the bearing structure may completely enclose the supporting structure.

In some arrangements, the bearing structure may be positioned between a connecting rod and a portion of the supporting structure such that longitudinal forces are transmitted from the connecting rod to the supporting structure through the bearing structure. That is, longitudinal forces applied to the link are directed through both the bearing structure and the supporting structure. In some arrangements, the supporting structure may be configured to transmit substantially all tensile forces to which the link is subjected, and the bearing structure may be configured to receive only compressive forces. In other arrangements, the bearing structure may be configured to transmit at least a portion of the tensile forces to which the link is subjected.

In addition, not only may the location of the bearing structure on a link vary, but also, the locations at which composite links are included in a modular conveyor belt may be strategically selected. Turn curve conveyor belts tend to load, in tension, the end of the belt located away from the center of the radius of curvature, whereas the inner end of the belt closest to the center of the radius may experience significantly less loading in tension. Thus, materials with higher tensile strengths may be utilized for links at an outer ends of the conveyor belt. For example, a higher ratio of supporting structure material relative to bearing structure material may be used for outer end links. Similarly, end links also may experience the most wear, as drive and/or guide mechanisms often engage with end links only, and not links located in a central portion of the belt. Therefore, bearing materials may be strategically used more generously in end links.

In addition, the relative sizes of the supporting structure and the bearing structure may vary to achieve desired characteristics. For example, in some arrangements, a volume of the supporting structure may be greater than <NUM> percent of total volume of the link. In other arrangements, the volume of the supporting structure may be equal to or less than <NUM> percent of the total volume of the link.

The supporting structure and the bearing structure may be formed of any suitable materials, such as materials having the relative properties mentioned above. For example, the supporting structure and/or the bearing structure may be at least partially formed of steel, brass, aluminum, ceramic, fiber reinforced material, plastic, and/or other suitable materials. In some arrangements, the supporting structure may be formed of a metal, to provide strength. For example, in some arrangements, the supporting structure may be formed of stainless steel. For instance, in arrangements in which the conveyor belt may be used for food handling processes, the supporting structure may be formed of stainless steel, especially in arrangements where the supporting may be only partially covered by bearing material, and thus, may be exposed to the food. Use of stainless steel may be prevent corrosion of the link, and may also prevent marking of the food by the link materials.

As noted above, in some arrangements, the supporting structure may have a tensile strength that is higher than the tensile strength of the bearing structure, and the bearing structure may be more resistant to wear than the supporting structure. These properties may be achieved by selecting suitable materials, as discussed above. Further, the processes of forming the selected materials and/or treatments of those materials may also contribute to the achievement of these properties. For example, the strength of metals may be augmented by formation processes such as forging, and the strength and/or wear resistance of non-metals may be enhanced by formation processes, such as crosslinking of polymers (plastics). Further, treatments, such as coatings, heat treating, quenching, and other treatments may be used to provide the materials with desired properties. In an exemplary embodiment, the supporting structure may be formed of metal and the bearing structure may be formed of plastic.

The bearing structure may be formed of a plastic material to provide wear resistance. In some arrangements, bearing structure may completely encase the supporting structure. In other arrangements, the bearing structure may only cover select portions of the supporting structure.

The bearing structure may be formed to cover the supporting structure in any suitable way. For example, in some arrangements, the bearing structure may be coated (e.g., dip-coated) over the inner supporting structure. In other arrangements, the two components may be co-molded. For example, the bearing structure may be overmolded over a pre-formed supporting structure. In some arrangements, bearing structure may be affixed to supporting structure using other methods, such as mechanical interlocking features, integrally-molded snap features, and/or fasteners. In some arrangements, the bearing structure may be removably coupled to the supporting structure.

<FIG> illustrate various details of composite link arrangements. As shown in <FIG> and <FIG>, in some arrangements, link <NUM> may be a composite link <NUM>. For example, in some arrangements, composite link <NUM> may include a supporting structure <NUM> and a bearing structure <NUM>. Supporting structure <NUM> may include a contour that establishes a shape of composite link <NUM>. In addition, supporting structure <NUM> may include apertures <NUM> that allow rods <NUM> from conveyor belt <NUM> (shown in <FIG>) to pass through composite link <NUM>. The bearing structure <NUM> includes apertures <NUM> that receive rods <NUM> from conveyor belt <NUM>, allowing rods <NUM> to pass through composite link <NUM> and associate with composite link <NUM>. Apertures <NUM> and apertures <NUM> may be disposed in longitudinally forward and rearward locations, respectively (i.e., at forward and trailing ends of the link legs). In some arrangements, however, the relative forward/rearward orientation of apertures <NUM> and <NUM> may be reversed. Composite link <NUM> may be formed and/or configured to contact and associate with rods <NUM> at surfaces of bearing structure <NUM> that are formed and/or configured to prevent contact between supporting structure <NUM> and rods <NUM>.

In some arrangements, a composite link may be formed by encasing (or partially encasing) a typical link structure with a bearing structure. For example, it will be noted that the shape of links <NUM> in <FIG> are substantially similar to supporting structure <NUM> in <FIG>. In other arrangements, a thinner or otherwise less robust supporting structure may be used, as the bearing structure may provide additional strength such that the combination of the supporting structure and the bearing structure has an overall strength that is comparable to a typical link structure formed of a single material.

As discussed herein, composite links <NUM> may be utilized by grid style conveyor belts, modular conveyor belts, and/or other conveyor belts known in the art. The size and configuration of composite links <NUM>, such as the type of apertures <NUM>, the shape of legs <NUM> or cross-members <NUM>, or the shape of composite link <NUM> itself, may vary according to the type of conveyor belt. For example, composite link <NUM> may be utilized by a turn curve belt, a straight running belt, a belt with steel rods, a belt with plastic rods, and so on. Thus, composite link <NUM>, including supporting structure <NUM> and/or bearing structure <NUM>, may be adapted based on its intended use, among other things.

In some arrangements, composite link <NUM> only contacts rod <NUM> at surfaces covered by bearing structure <NUM>. For example, in some arrangements, only select surfaces of supporting structure <NUM> may be overmolded with bearing structure <NUM>. As shown in the cross-sectional views of <FIG> and <FIG>, an aperture <NUM> defined by a plastic surface <NUM> of bearing structure <NUM> is the only surface available to receive and make contact with rod <NUM> of conveyor belt <NUM>. As shown in <FIG>, an engagement surface <NUM> of supporting structure <NUM> may define at least part of the aperture <NUM>. Further, as also shown in <FIG>, in some arrangements, bearing structure <NUM> may cover engagement surface <NUM> and may provide a contact surface <NUM> configured to contact a connecting rod inserted within aperture <NUM>. Thus, bearing structure <NUM> may prevent the connecting rod from contacting engagement surface <NUM>.

For example, in some arrangements, a steel, U-shaped metal link may be encased with a suitable plastic material. The steel, providing the shape and support to rods engaged with the link, does not contact the supported rods, because the plastic is placed between the metal rods and the metal link. The plastic inhibits the metal link from wearing down due to frictional forces between the metal rod and the metal link during operation of a conveyor belt. Additionally, the plastic inhibits the metal link from wearing down due to contact with other links (such as links adjacent to the metal link), contact with a drum that drives the conveyor belt, or other components of the conveyor belt that may contact a link, such as framework structure of the conveyor.

As discussed herein, composite links <NUM>, supporting structures <NUM>, and/or bearing structures <NUM> may be configured in a variety of ways. Further, composite links <NUM> may be manufactured or formed using a variety of processes known in the art. In some arrangements, supporting structure <NUM> may be formed by casting (such as die casting, centrifugal casting, shell casting, sand casting, and so on), plastic deforming, sheet metal forming, forging, stamping, machining, and so on. Once substantially formed, metal connecting structure <NUM> may be machined, or further machined, to achieve a desired shape.

Bearing structure <NUM> may be formed over supporting structure <NUM> in any suitable way. In some arrangements, bearing structure <NUM> may completely cover supporting structure <NUM>. In some arrangements, bearing structure <NUM> may be molded over only surfaces of supporting structure <NUM> that contact other components of conveyor belt <NUM>. For example, bearing structure <NUM> may include plastic material molded over a surface in contact with a rod, a surface in contact with another link, a surface in contact with a drum, and so on. For example, while bearing structure associated with apertures <NUM> is discussed above, bearing structure may also be provided at further rod contacting surfaces, such as the engagement surface of the supporting structure defining at least part of cross-member <NUM>, as shown in <FIG>.

In some arrangements, the thickness of bearing structure <NUM> may vary from one section of the link to another. <FIG> depicts composite link <NUM> having relatively thick bearing structure sections, such as a thick lower cross-member section <NUM> and a thick lower leg section <NUM>, and relatively thin sections, such as a thin tapered section <NUM> and a thin upper cross-member section <NUM>. In some cases, composite link <NUM> may have relatively thick sections at locations where link <NUM> contacts other components of conveyor belt <NUM>, and may have relatively thin sections where link <NUM> does not contact other components of the belt <NUM>. In some cases, the volume of the metal may be larger than the volume of the plastic at some or all sections of composite link <NUM>, in order to prevent wear without sacrificing strength. The specific ratio may be dependent on the type of conveyor belt <NUM> used, the type of materials used as supporting structure <NUM> and/or bearing structure <NUM>, or other factors. For example, the ratio may depend on certain failure characteristics of composite link <NUM>, such as on a ratio that prevents complete failure of the link when either supporting structure <NUM> or bearing structure <NUM> fails.

In some cases, the thickness may be defined based on an analysis of historical data associated with the wear of previously used links. For example, the analysis may determine that composite link <NUM> is more likely to break down due to wear at the cross-member than any other section of link <NUM>, for example due to wear from contact with rod <NUM> with cross-member <NUM>. Using the analysis, the thickness of lower cross-member section <NUM> of bearing structure <NUM> may be larger than the thickness at upper cross-member section <NUM>.

In some arrangements, at least one of the supporting structure and the bearing structure may comprise one continuous segment of the link. For example, in some arrangements, the bearing structure may be a unitary piece of material, as shown in <FIG>.

In other arrangements, however, at least one of the supporting structure and the bearing structure may comprise two or more discontinuous segments of the link. For example, in some arrangements, bearing structure <NUM> may be formed as multiple distinct pieces that cover sections of supporting structure <NUM> that contact rods <NUM> or other links. <FIG> depicts composite link <NUM> that includes multiple bearing structures <NUM> located at sections of link <NUM> that receive rods <NUM>. For purposes of illustration, rods <NUM> are shown in <FIG> in partially inserted configurations. Legs <NUM> of link <NUM> include a covering of first sections <NUM> of bearing structure <NUM>, and cross-member <NUM> of link <NUM> includes a covering of a second section <NUM> of bearing structure <NUM>. In some arrangements, bearing structure <NUM> may be utilized to engage and retain rod <NUM> at link <NUM>. Such a configuration is discussed in greater detail below.

<FIG> and <FIG> depict composite links <NUM> that include bearing structures <NUM> having multiple sections at various engagement surfaces of supporting structures <NUM>. Composite link <NUM> of <FIG> includes sections <NUM> and <NUM> of bearing structure <NUM> that cover apertures within legs <NUM> of supporting structure <NUM> as well as a section <NUM> that covers cross-member <NUM> of supporting structure <NUM>. Composite link <NUM> of <FIG> includes sections of bearing structure <NUM> that cover engagement surfaces of supporting structure <NUM>, such as a cross-member cover section <NUM> and a leg cover section <NUM>.

In some arrangements, the bearing structure may be configured to prevent conveyor belt components from contacting engagement surfaces of the supporting structure that are configured to engage a received or retained connecting rod. This configuration may enable a reduced amount of material to be used for the bearing structure, which may limit costs and weight.

<FIG> depicts composite link <NUM> having bearing structures <NUM> located only at surfaces of supporting structure <NUM> that engage a received or retained rod <NUM>. Contact surfaces <NUM> of bearing structures <NUM> may be configured or adapted to receive and retain rod <NUM>, providing a secure, reliable connection between composite link <NUM> and rod <NUM> while preventing or reducing the wear on composite link <NUM> due to the connection with rod <NUM>, among other things. In some arrangements, bearing structure <NUM> may be retained on supporting structure <NUM> by connecting rod <NUM>.

Supporting structure <NUM> may also be formed in a variety of configurations, depending on the characteristics of a conveyor belt and/or the utilization of composite link <NUM>. <FIG> depicts composite link <NUM> having a flat sheet configuration, including supporting structure <NUM> encased within bearing structure <NUM>. <FIG> depicts composite link <NUM> having a round wire configuration, including supporting structure <NUM> and multiple bearing structures <NUM>. <FIG> depicts composite link <NUM> having a single longitudinal member with hooks at either end to engage rod <NUM>, including supporting structure <NUM> and multiple bearing structures <NUM>. <FIG> depicts composite link <NUM> having a single longitudinal member with loops at either end to engage rod <NUM>, including supporting structure <NUM> and multiple bearing structures <NUM>. As will be readily apparent to those skilled in the art, other configurations, shapes, forms, and so on, may be utilized as a composite link <NUM>. For example, the supporting structure <NUM> may include multiple steel links attached or formed together, may include alternating metal and plastic links, and so on.

In some arrangements, supporting structure <NUM> may include features that facilitate or strengthen the attachment between supporting structure <NUM> and bearing structure <NUM>. <FIG> depicts composite link <NUM> that includes attachment holes <NUM> in supporting structure <NUM> capable of receiving plugs or extensions <NUM> of bearing structure <NUM>. Plugs <NUM> may facilitate attaching bearing structure <NUM> to supporting structure <NUM> via holes <NUM>, providing more bond strength between the structures, among other benefits. As will be apparent to those skilled in the art, other attachment mechanisms may be employed when assembling composite links <NUM>. For example, bearing structure <NUM> may be mechanically assembled to supporting structure <NUM>.

In some arrangements, bearing structure <NUM> is produced as a separate component and is subsequently attached to supporting structure <NUM>. <FIG> and <FIG> depict bearing structures <NUM> as separate components. In <FIG>, bearing structure <NUM> includes a leg coupling portion <NUM> configured to couple to leg <NUM> of supporting structure <NUM>, and a rod retaining portion <NUM> capable of receiving and retaining rod <NUM> for link <NUM>. Rod <NUM> may hold bearing structure <NUM> in place at leg <NUM> of supporting structure <NUM>. In <FIG>, bearing structure <NUM> is also formed as a separate component and includes leg coupling portion <NUM>, rod retaining portion <NUM>, and an aperture <NUM>. Thus, bearing structure <NUM> may be removably attachable to leg <NUM> of supporting structure <NUM>.

In some arrangements, the bearing structure <NUM> includes portions or sections utilized as certain components of conveyor belt <NUM>. <FIG> depicts composite link <NUM> having bearing structure <NUM> that includes a rod retaining portion <NUM> used to receive and retain rod <NUM>, and a contact surface portion <NUM> used to reduce the friction between a belt and other components of a conveyor system.

In some arrangements, at least one of the supporting structure and the bearing structure may comprise a portion of a product support surface attached to the link. For example, <FIG> depicts composite link <NUM> having bearing structure <NUM> that includes a rod retaining portion <NUM> used to receive and retain rod <NUM>, and a mesh portion <NUM> that acts as a portion of a center mesh for conveyor belt <NUM>, such as for brick-laid construction. That is, composite link <NUM> may include a first portion <NUM> that acts to link or otherwise associate rods <NUM> of conveyor belt <NUM> together and to the links <NUM>, and a second portion <NUM> that acts as a mesh or netting configured to support wares being carried by the conveyor belt, and prevent smaller pieces of carried items from falling between rods <NUM>. In some arrangements, although second portion <NUM> may be part of composite link <NUM>, second portion <NUM> may be provided without any of supporting structure <NUM>.

<FIG> depicts an embodiment of a turn curve conveyor belt <NUM>, including composite links <NUM>, associated rods <NUM>, and a sprocket <NUM> utilized as a driving mechanism for conveyor belt <NUM>. Sprocket <NUM> includes teeth <NUM> that, when sprocket <NUM> is turning, contact links <NUM> and provide force to drive links <NUM> and rods <NUM>. Links <NUM> include supporting structure <NUM> and one or more bearing structures <NUM>. For example, links <NUM> include rod contact surfaces <NUM>, upper tooth contact surfaces <NUM>, and lower tooth contact surfaces <NUM>. Thus, composite link <NUM> utilizes supporting structure <NUM> to associate rods <NUM> of belt <NUM>, and utilizes plastic bearing surfaces <NUM> to protect supporting structure <NUM> when in contact with other components of belt <NUM>, such as sprocket <NUM> and/or rods <NUM>.

As will be recognized by those in the art, in some arrangements the conveyor belt may be driven and/or guided by a drum <NUM>. In some arrangements, drum <NUM> may be a friction-based drum. In such arrangements, the surface of the drum <NUM> may have a coefficient of friction high enough to engage with the edge links of a belt without interconnecting or interdigitating with the drum. Sprocket-driven and drum-driven belts are discussed in greater detail in <CIT>, entitled "Conveyor Belt and System with a Non-collapsing Inside Edge,". In some arrangements, drum <NUM> may have an elastomeric surface or have a pliable surface coated with a substance that increases tackiness of the surface. In such cases, the plastic bearing surfaces described above may not only inhibit the wear of the edge links, but may also provide a more secure engagement between the edge link and the drum surface.

As will be recognized by those in the art, conveyor belt <NUM>, composite link <NUM>, bearing structure <NUM>, and/or supporting structure <NUM> may be formed in a variety of ways not specifically discussed herein. For example, the bearing structure <NUM> may include sections that facilitate attachment to rod <NUM>, allowing rod <NUM> to directly engage with a metal link, or bearing structure <NUM> may prevent wear between a buttonhead <NUM> and supporting structure <NUM>, and so on.

As will be apparent to one skilled in the art, composite links <NUM> described herein may be formed of materials other than metal and plastic. For example, composite link <NUM> may employ other materials as a supporting structure, such as certain plastics, wood, ceramics, and so on. Likewise, composite link <NUM> may employ various materials as a bearing structure, such as ceramics, resins, fabrics, and so on.

The features discussed herein may be used in many different types of conveyor belts and may be combined with other technologies intended to simplify the manufacturing of conveyor belts. For example, the composite link concepts mentioned above may be combined with rod receiving aperture alignment features to both ease proper aligning of rod receiving apertures and insertion of the rod and, further, securely retain the connecting rods once inserted.

While various arrangements of the current arrangements have been described, the description is intended to be exemplary, rather than limiting and it will be apparent to those of ordinary skill in the art that many more arrangements and implementations are possible that are within the scope of the current arrangements. Accordingly, the current arrangements are not to be restricted except in light of the attached claims and their equivalents. Features of any embodiment described in the present disclosure may be included in any other embodiment described in the present disclosure. Also, various modifications and changes may be made within the scope of the attached claims.

Further, in describing representative arrangements, the specification may have presented a method and/or process as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to a method and/or process should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied.

<FIG> illustrates another embodiment of a modular conveyor belt <NUM>. As illustrated in <FIG>, conveyor belt <NUM> may include a first pitch <NUM>, which may include a first link <NUM>. Conveyor belt <NUM> may further include a second pitch <NUM>, which may include a second link <NUM>. First link <NUM> and second link <NUM> may be connected (e.g., hingedly connected) by a connecting rod <NUM>. As shown in <FIG>, in some arrangements, the links of adjacent pitches may have substantially identical structures. Accordingly, first link <NUM> may have a substantially identical structure as second link <NUM>. Therefore, for purposes of discussion, only first link <NUM> will be described in detail. It should be noted that first pitch <NUM> and second pitch <NUM> are shown in <FIG> as having unitary structures, each comprised of plurality of links. In some arrangements, however, the links of each pitch may be individual components that are disposed laterally across the connecting rods, and thus, the links may rotate about the connecting rods relative to one another.

As with other arrangements discussed above, first link <NUM> may have a substantially U-shaped configuration, including an outer leg <NUM>, and inner leg <NUM>, and a cross-member <NUM> between outer leg <NUM> and inner leg <NUM>. First link <NUM> may further include a forward aperture <NUM>, an inner rearward aperture <NUM>, and an outer end aperture <NUM>. Apertures <NUM>, <NUM>, and <NUM> may be configured to receive connecting rods <NUM>.

In some arrangements, first link <NUM> may include a bearing structure <NUM> and a supporting structure <NUM>. Bearing structure <NUM> and supporting structure <NUM> may have characteristics and materials that are the same or similar to the bearing structures and supporting structures discussed above.

As shown in <FIG>, first link <NUM> may be an end link and may include a rod retaining feature formed by at least one of the bearing structure and the supporting structure. For example, as shown in <FIG>, first link <NUM> may include a rod recess <NUM> configured to house a free end of connecting rod <NUM> once fully inserted. In order to retain rod <NUM> within recess <NUM> and prevent rod <NUM> from withdrawing from outer end aperture <NUM>, first link <NUM> may include a rod retaining ridge <NUM> proximate outer end aperture <NUM>. Rod retaining ridge <NUM> may be defined, at least in part, by bearing structure <NUM>. Rod retaining ridge <NUM> may include a laterally oriented ridge configured to inhibit the longitudinal translation of the connecting rod.

<FIG> is a perspective, cut-away, partial cross-sectional view of first link <NUM>. The inner end of first link <NUM> is illustrated in <FIG> in a truncated fashion. However, in some arrangements, first link <NUM> may have a substantially similar form as a stand alone, individual link.

<FIG> also shows additional detail regarding rod retaining ridge <NUM>. In some arrangements, rod retaining ridge may have the form of a detent. For example, as shown in <FIG>, rod retaining ridge <NUM> may include a sloped forward wall <NUM> and a sloped rearward wall <NUM>. As shown in <FIG>, forward wall <NUM> and rearward wall <NUM> may have a concave curvature. In other arrangements, forward wall <NUM> and/or rearward wall <NUM> may have a relatively planar configuration or a convex configuration. Further, in some arrangements, ridge <NUM> may have a substantially semi-circular cross sectional shape. Also, as shown in <FIG>, ridge <NUM> may terminate at an end wall <NUM>.

In some arrangements, inner aperture <NUM> and outer aperture <NUM> may have longitudinally elongate/slotted configurations, as shown in <FIG>. This configuration may enable an inserted connecting rod to longitudinally translate within apertures <NUM> and <NUM>. The connecting rod may be inserted into aperture <NUM> and into the forward end of inner aperture <NUM> in a rod insertion and withdrawal position. In order to secure the connecting rod in first link <NUM>, the connecting rod may then be longitudinally translated beyond rod retaining ridge <NUM> and toward the rearward end of inner aperture <NUM>. It should also be noted that, in some arrangements, inner aperture <NUM> may have two components, such as an inner opening <NUM> and an outer opening <NUM>, for example due to a central opening within inner link leg <NUM>.

<FIG> illustrates an enlarged, perspective, cut-away, cross-sectional view of first link <NUM>. As shown in <FIG>, outer end aperture <NUM> may be defined by a curved wall <NUM>. In addition, recess <NUM> may be defined, at least in part, by an end wall <NUM>, which prevents movement of the connecting rod in a lateral direction when retained in recess <NUM> by rod retaining ridge <NUM>. Also, as further shown in <FIG>, first link <NUM> may include a central opening <NUM> in outer link leg <NUM>. Such a central opening may enable use of a reduced amount of material for bearing structure <NUM> and/or supporting structure <NUM>.

Alternatively, or additionally, other configurations of rod retaining features may also be implemented. For example, in some arrangements, the rod retaining feature may include a mechanical attachment, rigidly connecting the rod to the first link. In addition to the protective benefits, incorporating features in bearing structure <NUM> to retain rod <NUM> may eliminate the need to weld rod <NUM> to link <NUM>, among other things. Arrangements of such link rod retaining features are more fully disclosed in <CIT>, entitled "Conveyor Belt and Method of Assembly. " Additional rod retaining features are disclosed in U. Patent Numbers ___,___,___, ___, and ___, currently <CIT>; <CIT>; <CIT>; <CIT>; and<CIT>, and is entitled "Conveyor Belt Link with Rod Retaining Feature.

Claim 1:
A modular conveyor belt (<NUM>, <NUM>), comprising:
at least a first link (<NUM>, <NUM>) and a second link (<NUM>, <NUM>); and
an elongated connecting rod configured to hingedly attach the first link and the second link to one another;
wherein the first link (<NUM>, <NUM>) includes a supporting structure (<NUM>, <NUM>) formed of a first material and a bearing structure (<NUM>, <NUM>) formed of a second material covering at least a portion of the supporting structure (<NUM>, <NUM>), the supporting structure (<NUM>, <NUM>) having a tensile strength that is higher than the bearing structure (<NUM>, <NUM>), and the bearing structure (<NUM>, <NUM>) being more resistant to wear than the supporting structure (<NUM>, <NUM>),
wherein the bearing structure (<NUM>, <NUM>) prevents the supporting structure (<NUM>, <NUM>) from contacting at least the connecting rod,
wherein the link has a substantially U-shaped configuration formed by two substantially longitudinally oriented legs (<NUM>, <NUM>, <NUM>) each having rod apertures (<NUM>, <NUM>; <NUM>, <NUM>, <NUM>) at forward and trailing ends and a laterally oriented cross-member (<NUM>, <NUM>) between the two legs,
characterized in that
the bearing structure (<NUM>, <NUM>) is configured to prevent contact between the rod and the supporting structure (<NUM>, <NUM>) at the apertures at the forward and the trailing ends and a portion of the bearing structure (<NUM>, <NUM>) is disposed such that, when a conveyor belt connecting rod (<NUM>, <NUM>) is positioned through the apertures (<NUM>, <NUM>; <NUM>, <NUM>, <NUM>) at the forward ends of the legs of the first link, the bearing structure (<NUM>, <NUM>) is located at a rod contacting surface of the cross-member.