Patent Description:
This disclosure relates to fasteners for conveyor belts and, more specifically, to fasteners for conveyor belts containing cables.

Steel cable conveyor belts contain rubber and cables embedded in the rubber that extend the length of the conveyor belt. The steel cables often have a diameter in the range of <NUM> to <NUM>. The cables provide tensile strength to the conveyor belt as the conveyor belt is loaded with conveyed material and goes over and around pulleys along the path of the conveyor belt. The tension in each cable is shared with nearby cables by rubber that extends between the cables and which is placed in shear as the cables are placed in tension.

Steel cable conveyor belts are typically used in heavy duty applications that involve material conveyed on the conveyor belt being measured in tons (<NUM> ton = <NUM> tonnes = <NUM>), the conveyor belt can extend a half mile or more (<NUM> mile = <NUM>), and the conveyor belt being <NUM> (four feet) wide or more. Steel cable conveyor belts must have high strength to withstand these applications and have working load ratings that range from <NUM> kN/m width (<NUM> pounds per inch width (PIW)) to <NUM> MN/m width (<NUM>,<NUM> PIW). Given the size and construction of steel cable conveyor belts, it is often difficult to repair a steel cable belt when the belt is damaged. Steel cable conveyor belts may be damaged by, for example, a very heavy object falling onto the conveyor belt or an object tearing the belt.

Connecting the ends of a new steel cable conveyor belt, or repairing a severely damaged steel cable conveyor belt is a complicated process that requires a high degree of skill, specialized tools, and a large amount of time. Conventional installation and repair protocols involve a facility shutting down the conveyor and requesting a specialized team visit the facility to install or repair the conveyor belt. Facilities utilizing steel cable conveyor belts are often in remote areas such that it may be several days before a team can reach the facility.

For a repair, when the repair team arrives at the facility, a temporary shelter is erected to protect the damaged section of the conveyor belt from the environment. The damaged section of belting is identified and the entire damaged section is typically removed by cutting the section out completely. This leaves the ends of the conveyor belt to either be joined together with a single splice or joined together with a new length of belt (sometimes referred to as a "saddle"). When a saddle is used to join the ends, the repair operation involves creating two splices, i.e., one splice between one belt end and the saddle and another belt splice between the other belt end and the saddle.

To prepare the conveyor belt for splicing, the team first pulls off a top cover of the belt at one of the freshly cut ends of the remaining undamaged conveyor belt, separates the cables from the rubber of a lower cover of the conveyor belt at the one end, and pulls off the lower cover at the one end. Any rubber remaining on the cables is trimmed off by hand. The cables are then cut to have lengths according to splice instructions from the steel cable belt manufacturer. The preparation process is repeated at the other end of the conveyor belt.

The team positions a lower platen of a vulcanizing press below the conveyor belt ends. Vulcanizing presses for steel cable conveyor belts are often very large and require a crane to lift the vulcanizing press into position. The cables of the conveyor belt ends are cleaned and specialized cement is applied to the cables to prepare the cables to bond with the rubber of the splice. Next, a lower cover of the splice is positioned below the cables and the cables are arranged in a pattern according to the splice instructions from the conveyor belt manufacturer. Uncured rubber noodles and gap filler are used to fill the areas between the cables. An upper cover of the splice is then positioned on the cables.

Using a crane, the upper platen of the vulcanizing press is positioned on the upper cover to sandwich the upper cover, steel cables, and lower cover between the upper and lower platens of the press. The vulcanizing press is operated to raise the temperature of the splice to a predetermined temperature and compress the splice with a predetermined pressure. After the vulcanization process is complete, the team uses the crane to remove the upper platen. The splice is lifted off of the lower platen so that the splice may cool. The lower platen is subsequently removed from the conveyor belt and the conveyor belt is ready for use. For higher tensions, splice length can be upwards of <NUM> (<NUM> feet) or more and require multiple vulcanizing cycles as the presses are not long enough to cook the entire splice length and must be moved longitudinally along the splice length.

As will be appreciated, the conventional approach for repairing a steel cable conveyor belt is labor and time intensive and may take several days to get the conveyor belt up and running again. This downtime adversely affects the productivity of the facility, especially for large-scale operations that depend on the conveyor belt to carry tons of aggregate or other material every hour.

Fasteners for conveyor belts comprising crimps and stop bodies are known from <CIT>, <CIT>, <CIT> and <CIT>.

In accordance with the present invention, a fastener is provided for securing to a conveyor belt end having a cable. The fastener includes a crimp configured to be fixed to the cable and a fastener body. The fastener body has a longitudinally extending upper plate portion, a longitudinally extending lower plate portion, and a loop portion connecting the upper and lower plate portions. The fastener includes a stop body configured to fit between the upper and lower plate portions of the fastener body and abut the crimp with the crimp longitudinally intermediate the stop body and the loop portion. The fastener further includes an attachment member configured to extend through apertures of the upper and lower plate portions of the fastener body and clamp the upper and lower plate portions to the stop body so that the upper and lower plate portions resist movement of the stop body. The stop body abuts the crimp to take up the tension from the cable and the attachment member holds the stop body in clamped engagement in the fastener body. With the fastener body connected to the cable, a hinge pin may be advanced through the loop. In this manner, the fastener provides a durable construct for being attached to the conveyor belt cable that may be used to form a mechanical splice between conveyor belt ends.

To enable a better understanding of the present invention, and to show how the same may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings, in which:-.

With reference to <FIG>, a splice <NUM> for joining ends <NUM>, <NUM> of a conveyor belt <NUM> is shown. The splice <NUM> includes fasteners <NUM> that are each secured to one of the conveyor belt ends <NUM>, <NUM> to form a plurality of fasteners <NUM> on the opposite conveyor belt ends <NUM>, <NUM>. The fasteners <NUM> each include one or more loops <NUM> that are interlaced with the loops <NUM> of the fastener <NUM> longitudinally aligned therewith. The laced loops <NUM> define a passageway through which a hinge pin <NUM> can be inserted to hingedly connect the belt ends. The ends of the hinge pin <NUM> are shown protruding from the lateral sides of the conveyor belt ends <NUM>, <NUM> for illustrative purposes but would, in operation, be generally flush with the lateral sides of the conveyor belt ends <NUM>, <NUM>. As the splice <NUM> travels in a downstream, longitudinal direction, the fasteners <NUM> can pivot about the hinge pin <NUM> which provides flexibility to the splice <NUM>.

The conveyor belt <NUM> is made of one or more layers of an elastomeric material, such as a natural or a synthetic rubber, and includes longitudinally extending cables <NUM> (see <FIG>) to provide tensile strength for the belt <NUM>. The cables <NUM> may be made of steel and are embedded in the rubber of the conveyor belt <NUM>. The conveyor belt <NUM> has a rated working load limit in the range of <NUM> kN/M width to <NUM> MN/m width (<NUM> PIW to <NUM>,<NUM> PIW). Each fastener <NUM> is fixed to two of the cables <NUM>, which permits the fastener <NUM> to have a narrow lateral width so that the fastener <NUM> readily accommodates troughing of the conveyor belt <NUM>. In other embodiments, each fastener <NUM> may be fixed to one, three, four, or another number of cables <NUM> as desired. The components of the fasteners <NUM> and hinge pm <NUM> are made of metallic materials, and provide a high-strength, mechanical connection between the cables <NUM> of the conveyor belt <NUM>. Further, the fasteners <NUM> may be quickly connected to the cables <NUM> and used to join the ends of the conveyor belt <NUM> without having to utilize a vulcanizing press which reduces downtime of the conveyor belt <NUM>. For example, the fasteners <NUM> may be used to form a hinged splice of the belt <NUM> in a few hours, such as four to eight hours, using common tools and without special training unlike a vulcanizing process. In some applications, the fasteners <NUM> may be used only temporarily, such as days or weeks, to keep the conveyor belt <NUM> running until the repair team can arrive and splice the conveyor belt <NUM> using a vulcanizing press. In other applications, the fasteners <NUM> may be employed for longer time periods, such as months.

Regarding <FIG>, the fastener <NUM> includes an outboard portion <NUM> and an inboard portion <NUM>. The fastener <NUM> includes a fastener body <NUM> having an upper portion such as an upper plate <NUM>, a lower portion such as a lower plate <NUM>, and one or more loops <NUM> connecting the upper and lower plates <NUM>, <NUM>. The fastener body <NUM> includes recesses <NUM> laterally adjacent the loops <NUM> for receiving the loops <NUM> of the longitudinally aligned fastener <NUM> on the opposite side of the hinge pin <NUM>. The upper and lower plates <NUM>, <NUM> define therebetween a gap <NUM> that receives one or more crimps, such as ferrules <NUM>, and the fastener <NUM> has a stop <NUM> that limits inboard movement of the ferrules <NUM> and cables <NUM> fixed thereto. In one embodiment, the stop <NUM> includes a stop body such as a ferrule support <NUM> separate from the fastener body <NUM>. In another embodiment, the stop <NUM> of the fastener <NUM> may be a portion of the fastener body <NUM>, as an example.

The ferrules <NUM> are crimped onto end portions <NUM> (see <FIG>) of the cables <NUM> and portions of the cables <NUM> exposed from the belt material extend in receptacles, e.g., through openings <NUM> (see <FIG>), of the ferrule support <NUM>. The fastener <NUM> further includes one or more attachment members, such as rivets, screws, or bolts, for extending through openings <NUM>, <NUM> of the upper plate <NUM> and through openings <NUM>, <NUM> of the lower plate <NUM> and connecting the upper and lower plates <NUM>, <NUM>. In one embodiment, the attachment members include bolts <NUM>, <NUM> that engage nuts <NUM>, <NUM> (see <FIG>) received in the through openings <NUM>, <NUM> of the lower plate <NUM>. Tightening the bolts <NUM>, <NUM> causes the upper and lower plates <NUM>, <NUM> to clamp the ferrule support <NUM> therebetween. When tension is applied to the cables <NUM>, the ferrules <NUM> abut the ferrule support <NUM> and the ferrule support <NUM> inhibits pull- through in direction <NUM> (see <FIG>) of the ferrules <NUM> and cable end portions <NUM> secured therein from the fastener body <NUM>.

In one embodiment, the ferrules <NUM> each have an initial, undeformed configuration wherein the ferrule <NUM> is tubular. The undeformed ferrule <NUM> may have a sidewall with a circular cross-section so that the ferrule <NUM> has a cylindrical configuration with a smooth cylindrical outer surface. The inner diameter of the undeformed ferrule <NUM> is larger than an outer diameter of the end portion <NUM> of the associated cable <NUM> to permit the ferrule <NUM> in the undeformed configuration thereof to be slid on to the cable end portion <NUM>. The ferrule <NUM> further has a crimped, deformed configuration wherein the ferrule <NUM> has an inner diameter that is smaller than the inner diameter of the ferrule <NUM> when the ferrule <NUM> is in the initial, undeformed configuration. In the deformed configuration, each ferrule <NUM> has compressed portions <NUM> separated by flanges such as annular ribs <NUM> as shown in <FIG>. The ribs <NUM> are formed by material flowing away from the deformed compressed portions <NUM> during the crimping process. The deformed configuration of the ferrules <NUM> is generally defined by dies of the tool used to deform the ferrules <NUM> and may be different for different applications.

With reference to <FIG>, the crimping process advantageously forms one of the ribs 152A at an inboard end portion <NUM> of the ferrule <NUM>. The rib <NUM> has an enlarged, annular surface <NUM> for abutting a surface <NUM> of the ferrule support <NUM> and resisting pull- through of the ferrule <NUM> and cable <NUM> secured therein with cups or countersinks <NUM>, <NUM> and ridges <NUM>, <NUM> of the plates <NUM>, <NUM> resisting inboard movement of the ferrule support <NUM> to keep loading on the bolt <NUM> to a minimum. Accordingly, the ferrule <NUM> provides a generally rigid structure on the cable end portion <NUM> that is enlarged relative to the opening <NUM> of the ferrule support <NUM>. In this manner, during conveyor belt operation, tension in the splice is transferred from the cables <NUM> to the ferrule support <NUM> and the fastener body <NUM> clamping the ferrule support <NUM> which, in turn, transfers this loading to the hinge pin <NUM>.

During installation of the fastener <NUM> on two of the cables <NUM>, the ferrules <NUM> are first secured to the end portions <NUM> of the cables <NUM> by advancing an end portion <NUM> of each cable <NUM> in direction <NUM> (see <FIG>) into a throughbore <NUM> (see <FIG>) of one of the ferrules <NUM>. The ferrules <NUM> are crimped onto the end portions <NUM> of the cables <NUM> by deforming the material of the ferrules <NUM>. The ferrule support <NUM> is positioned onto the cables <NUM> so that the cables <NUM> extend through the two through openings <NUM> of the ferrule support <NUM> after the ferrules <NUM> have been applied to the end portions <NUM> of the cables <NUM>. In an alternative approach, the ferrule support <NUM> is positioned on the cables <NUM> before the ferrules <NUM> have been applied to the cables <NUM>. In either approach, once the ferrules <NUM> and ferrule support <NUM> have been applied to the end portions <NUM> of the cables <NUM>, the cable end portions <NUM> with the ferrules <NUM> and ferrule support <NUM> thereon are positioned in the gap <NUM> between the upper and lower plates <NUM>, <NUM> of the fastener body <NUM>.

In one approach, the fastener body <NUM> is connected to the assembly of the ferrule support <NUM>, ferrules <NUM>, and cable end portions <NUM>, by advancing the fastener body <NUM> in longitudinal direction <NUM> (see <FIG>). Advancing the fastener body <NUM> in longitudinal direction <NUM> engages the ridges <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM> with the outboard end of the ferrule support <NUM> and causes the ferrule support <NUM> to cam apart the upper and lower plates <NUM>, <NUM>. The fastener body <NUM> is continued to be advanced in longitudinal direction <NUM> onto the ferrule support <NUM> until the ridges <NUM>, <NUM> are inboard of the ferrule support <NUM> and the outboard countersinks <NUM>, <NUM> (see <FIG>) of the upper and lower plates <NUM>, <NUM> are aligned with the openings <NUM>, <NUM> (see <FIG> and <FIG>) of the ferrule support <NUM>. The upper and lower plates <NUM>, <NUM> then snap back together and the countersinks <NUM>, <NUM> seat in the openings <NUM>, <NUM> (see <FIG> and <FIG>) of the ferrule support <NUM>.

Next, a shank portion <NUM> (see <FIG>) of the bolt <NUM> is advanced through the opening <NUM> of the upper plate <NUM>, through a through opening <NUM> of the ferrule support <NUM>, and into threaded engagement with the nut <NUM> that is fixed against rotation in the through opening <NUM> (see <FIG>) of the lower plate <NUM>. The shank portion <NUM> of the bolt <NUM> is then advanced through the opening <NUM> of the upper plate <NUM>, into the rubber of the belt <NUM>, between the cables <NUM>, and into threaded engagement with the nut <NUM> received in the through opening <NUM> of the lower plate <NUM>. To permit advancing the shank portion <NUM> of the bolt <NUM> through the rubber of the belt <NUM>, an installer may predrill a hole in the rubber of the belt <NUM> to accommodate the bolt <NUM>. Alternatively, the bolt <NUM> may be provided with a pointed pilot shank detachably mounted to the end of the shank portion <NUM> to pierce the rubber. As yet another example, the bolt <NUM> may pilot itself through the rubber if the bolt <NUM> has an appropriately configured leading end. The bolts <NUM>, <NUM> are then tightened which causes the upper and lower plates <NUM>, <NUM> to clamp the ferrule support <NUM> therebetween and causes end portions <NUM>, <NUM> (see <FIG>) of the upper and lower plates <NUM>, <NUM> to compress a tongue or skived portion <NUM> (see <FIG>) of the conveyor belt <NUM> therebetween.

With the ferrule support <NUM> clamped between the upper and lower plates <NUM>, <NUM>, the ferrule support <NUM> is firmly held between the upper and lower plates <NUM>, <NUM> and the ridges <NUM>, <NUM> and countersinks <NUM>, <NUM> of the plates <NUM>, <NUM> resist movement of the ferrule support <NUM> and the ferrules <NUM> in pull-through direction <NUM> as shown in <FIG>. Further, the bolt <NUM> and nut <NUM> inhibit the separation of the end portions <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM> as the conveyor belt <NUM> travels over pulleys. The engagement between the bolt <NUM> and the nut <NUM> also maintains compression of the skived portion <NUM> of the conveyor belt <NUM> so that the compressed, skived portion <NUM> operates as a strain relief that protects the cables <NUM> from premature fatigue damage in bending.

With reference to <FIG> and <FIG>, the fastener body <NUM> includes a ferrule support stop <NUM> for limiting movement of the ferrule support <NUM> in pull-through direction <NUM>, In one embodiment, the ferrule support stop <NUM> includes the or countersinks <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM> that extend inward distances <NUM>, <NUM> from inner surfaces <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM>. The countersinks <NUM>, <NUM> have a wider inner diameter at outer surfaces <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM> and a narrower inner diameter at the inner surfaces <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM>. The countersinks <NUM>, <NUM> may be formed by dimpling the material of the upper and lower plates <NUM>, <NUM> to form annular walls or wall portions 92A, 94A that taper down inwardly into the gap <NUM>. When the ferrule support <NUM> has been positioned in the gap <NUM> between the upper and lower plates <NUM>, <NUM>, the countersinks <NUM>, <NUM> extend into openings <NUM>, <NUM> (see <FIG> and <FIG>) of the ferrule support <NUM> so that the countersinks <NUM>, <NUM> and openings <NUM>, <NUM> cooperate to form at least a portion of the ferrule support stop <NUM>. The countersink wall portions 92A, 94B have outer surfaces <NUM>, <NUM> (see <FIG>) that mate with beveled surfaces <NUM>, <NUM> (see <FIG> and <FIG>) of the ferrule support <NUM>. The mating fit between the ferrule support <NUM> and the countersinks <NUM>, <NUM> rigidly connects the ferrule support <NUM> to the upper and lower plates <NUM>, <NUM> once the bolt <NUM> has been tightened down. Further, the mating fit between the ferrule support <NUM> and counter sinks <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM> and the engagement of the ferrule support <NUM> against the ridges <NUM>, <NUM> transfers the tensile load from the cable <NUM> to the fastener body <NUM>. The bolts <NUM>, <NUM> are subject to much lower stresses because the bolts <NUM>, <NUM> only carry the damping forces and do not carry the tensile load directly. This helps limit back-out or failure of the bolts <NUM>, <NUM>.

With reference to <FIG> and <FIG>, the ferrule support stop <NUM> further includes one or more protrusions, such as ridges <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM>. The ridges <NUM>, <NUM> extend inward by distances <NUM>, <NUM> from the inner surfaces <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM>. The distances <NUM>, <NUM> may be larger than distances <NUM>, <NUM>. When the ferrule support <NUM> is clamped between the upper and lower plates <NUM>, <NUM> via the bolt <NUM>, the ferrule support <NUM> has an inboard facing wall <NUM> (see <FIG>) that abuts the ridges <NUM>, <NUM> and resists pull-through of the ferrule support <NUM> in direction <NUM>. The ridges <NUM>, <NUM> effectively reduce the vertical dimension of the gap <NUM> to an area smaller than the wall <NUM> of the ferrule support <NUM> to block the ferrule support <NUM> from shifting out in direction <NUM> from between the upper and lower plates <NUM>, <NUM> of the fastener body <NUM> as tension is applied to the fastener <NUM> during conveyor belt operations.

With reference to <FIG>, the upper and lower plates <NUM>, <NUM> include countersinks <NUM>, <NUM> having tapered annular walls or wall portions 134A, 136A extending about the openings <NUM>, <NUM> and which receive the bolt <NUM>, The countersinks <NUM>, <NUM> of the upper plate <NUM> may have the same or different geometry and the countersinks <NUM>, <NUM> of the lower plate <NUM> may likewise have the same or different geometry. Further, the vertically aligned countersinks <NUM>, <NUM> and <NUM>, <NUM> may have the same or different geometry. For example, the countersink <NUM> may be wider than the countersink <NUM> to accommodate the nut <NUM> as shown in <FIG>.

With reference to <FIG>, the countersinks <NUM>, <NUM> of the upper plate <NUM> include beveled surfaces <NUM>, <NUM> extending about the openings <NUM>, <NUM> against which head portions <NUM> (see <FIG>) of the bolts <NUM>, <NUM> may seat. The countersinks <NUM>, <NUM> of the lower plate <NUM> each include one or more recesses <NUM> sized to receive one or more projections, such as tabs <NUM> (see <FIG>) of the nuts as <NUM>, <NUM>. As shown in <FIG>, the recesses <NUM> of the countersinks <NUM>, <NUM> may be diametrically opposed and oriented along a longitudinal axis <NUM> of the fastener body <NUM>. When the nuts <NUM>, <NUM> are positioned in the countersinks <NUM>, <NUM> and the tabs <NUM> extend in the recesses <NUM> thereof, the nuts <NUM>, <NUM> are kept from turning relative to the lower plate <NUM> as the bolts <NUM>, <NUM> are turned and threaded into the nuts <NUM>, <NUM>. In one embodiment, the fastener body <NUM> is provided with the nuts <NUM>, <NUM> preassembled in the lower plate <NUM>. For example, the nuts <NUM>, <NUM> may be welded to the lower plate <NUM>. In another approach, the bolts <NUM>, <NUM> may have one or more projections that engage one or more recesses of the countersinks <NUM>, <NUM> to limit turning of the bolts <NUM>, <NUM> relative to the upper plate <NUM> as the nuts <NUM>, <NUM> are tightened onto shank portions <NUM> of the bolts <NUM>, <NUM>.

With reference to <FIG>, a crimp tool is used to compress the ferrules <NUM> onto the cables <NUM>. In one embodiment, the tool has dies that form four compressed portions 150A, 150B, 150C, 150D as the tool crimps the ferrule <NUM> onto the cable <NUM>. The dies may be configured to crimp two ferrules <NUM> onto two cables <NUM> at a time. The tool compresses the material of the side wall of the ferrule <NUM> into the outer strands of the cable <NUM>. The dies of the tool have recesses that permit the compressed material of the side wall to flow radially outward and form the ribs <NUM>. After crimping, the ferrules <NUM> each have a side wall <NUM> with the ribs <NUM> and compressed portions <NUM> formed therein. In other embodiments, the tool dies may not have recesses such that the deformed ferrules <NUM> do not have ribs <NUM>. The dies of the crimp tool may include a surface that is positioned against the end of the cable <NUM> and locates the dies along the cable <NUM>. This makes it easier for an installer to locate the ferrules <NUM> at uniform locations on the ends of the cables <NUM>.

With reference to <FIG>, the rib 152A of the ferrule <NUM> includes the surface <NUM> and the ferrule support <NUM> includes a ferrule-facing wall <NUM> having the surface <NUM> thereon. When the conveyor belt <NUM> is placed in tension, the cables <NUM> pull the ferrules <NUM> in direction <NUM> and the hinge pm <NUM> pulls the fastener body <NUM> in direction <NUM>. The ferrule support <NUM> is fixed to the fastener body <NUM> via the engaged surfaces <NUM>, <NUM> and <NUM>, <NUM>, the ferrule support <NUM> abutting the ridges <NUM>, <NUM>, and the upper and lower plates <NUM>, <NUM> clamping the ferrule support <NUM> therebetween. As the ferrules <NUM> are pulled in direction <NUM> against the wall <NUM> of the ferrule support <NUM>, the ferrule support <NUM> applies a reaction force in direction <NUM> that resists movement of the ferrules <NUM> in direction <NUM>.

With reference to <FIG> and <FIG>, the ferrules <NUM> include through bores <NUM> that receive the cables <NUM> and the ferrule support <NUM> includes through openings <NUM> that are aligned with and open to the through bores <NUM> of the ferrules <NUM>. The through openings <NUM> of the ferrule support <NUM> are configured to form a loose slip-fit with the cables <NUM> when the ferrule support <NUM> is initially positioned on the cables <NUM>. Once the fastener <NUM> has been secured to the cables <NUM>, the through openings <NUM> are large enough that the ferrule support <NUM> is spaced from the cables <NUM> over the outer diameter of the cables <NUM>. The clearance between the ferrule support <NUM> and the cables <NUM> permits the cables <NUM> to move between the upper and lower plates <NUM>, <NUM> inboard of the connection between the cables <NUM> and the ferrule <NUM>. As shown in <FIG>, the ferrules <NUM> and ferrule support <NUM> have axes <NUM>, <NUM> extending through the through openings <NUM> and through bores <NUM> along which the cables <NUM> will extend when the fastener <NUM> is secured to the cables <NUM>.

With reference to <FIG>, the ferrule support <NUM> includes a saddle portion <NUM> for contacting the cables <NUM> when the ferrule support <NUM> is initially positioned on the cables <NUM>. The ferrule support <NUM> includes an upper wall <NUM> and curved surfaces <NUM>, <NUM> extending about the through openings <NUM> that are contoured to complement and provide clearance from the outer surfaces of the cables <NUM> when the fastener <NUM> is secured to the cables <NUM>. The ferrule support <NUM> includes side walls <NUM>, <NUM> depending from the upper wall <NUM> and including ledge portions <NUM>, <NUM> that extend around the underside of the cables <NUM>. The ferrule support <NUM> has a lower opening <NUM> defined between the ledge portions <NUM>, <NUM>. The ferrule support <NUM> may be connected to a pair of cables <NUM> by advancing the ferrule support <NUM> in direction <NUM> down onto the cables <NUM> before or after the ferrules <NUM> have been applied to the cables <NUM>. The ferrule support <NUM> may be advanced in direction <NUM> so that both cables <NUM> enter the lower opening <NUM> at the same time or maybe advanced so that a first cable <NUM> enters the lower opening <NUM> before a second cable <NUM>. When one cable <NUM> is installed at a time, the ferrule support <NUM> is shifted in direction <NUM> onto the first cable <NUM> so that the first cable <NUM> enters the lower opening <NUM> and one of the surfaces <NUM>, <NUM> seats against the first cable <NUM>. The steel cables <NUM> have a set orientation or pitch in the conveyor belt <NUM>. The term pitch is often used to describe the distance between the center line of one cable <NUM> to the next cable <NUM>. The ferrule support <NUM> is configured so that the first cable <NUM> and a second cable <NUM> have a lateral width across the cables <NUM> that is larger than a width <NUM> (see <FIG>) of the opening <NUM>. Thus, to position the ferrule support <NUM> on the second cable <NUM>, the end portion <NUM> of the second cable <NUM> is deflected laterally toward the first cable <NUM> to temporarily decrease the spacing between the end portions <NUM> of the first and second cables <NUM> and permit the second cable <NUM> to be laterally close enough to the first cable <NUM> to enter the lower opening <NUM> of the ferrule support <NUM>. The ferrule support <NUM> is then advanced onto the second cable <NUM> and the second cable <NUM> is released by the installer. The second cable <NUM> resiliently shifts laterally away from the first cable <NUM> to restore the original pitch of the cables <NUM>. The resilient bias of the cables <NUM> to return back to their original pitch holds the ferrule support <NUM> in position on the cables <NUM>. In another approach, the ferrule support <NUM> may be slid longitudinally onto the cables <NUM> before connecting the ferrules <NUM> by advancing the end portions <NUM> of the cables <NUM> into the through openings <NUM> of the ferrule support <NUM> until the ferrule support <NUM> is at the desired longitudinal position along the cables <NUM>.

With reference to <FIG>, the vertically oriented countersink through opening <NUM> of the ferrule support <NUM> may have a non-circular configuration. In one embodiment, the through opening <NUM> includes a fastener-receiving center portion <NUM> and lateral side or lobe portions <NUM>, <NUM>. The lobe portions <NUM>, <NUM> provide clearance for the cables <NUM> as the cables <NUM> extend through the ferrule support <NUM>. More specifically, the portion of the ferrule support <NUM> having the beveled surface <NUM> thereon extends downwardly and would intersect the outer diameter of the cables <NUM> if the through opening <NUM> did not include the lobe portions <NUM>, <NUM>. The lobe portions <NUM>, <NUM> thereby provide clearance for the cables <NUM> to seat in the ferrule support <NUM> without interference from the beveled surface <NUM>. Regarding <FIG>, the ferrule support <NUM> has surfaces <NUM> on opposite sides of the center portion <NUM>. The surfaces <NUM> are configured to be in clearance with the bolt <NUM> as the bolt <NUM> extends through the through opening <NUM>.

With reference to <FIG>, the beveled surface <NUM> of the ferrule support <NUM> may include a first portion <NUM> on the side wall <NUM> and a portion <NUM> on the side wall <NUM>. In this manner, the beveled surface portions <NUM>, <NUM> can engage opposite sides of the countersink <NUM> of the lower plate <NUM>. The surface portions <NUM>, <NUM> mate with the outer surface <NUM> of the countersink <NUM> and limit longitudinal and lateral movement of the ferrule support <NUM> relative to the lower plate <NUM>.

With the ferrules <NUM> and ferrule support <NUM> on the cables <NUM>, the fastener body <NUM> may be connected thereto by advancing the fastener body <NUM> in direction <NUM> (see <FIG>) so that the ferrule support <NUM> engages the ridges <NUM>, <NUM> and cams apart the upper and lower plates <NUM>, <NUM>. Once the countersinks <NUM>, <NUM> and ridges <NUM>, <NUM> of the fastener body <NUM> have been advanced in direction <NUM> inboard beyond the ferrule support <NUM>, the ridges <NUM>, <NUM> shift together inboard of the ferrule support <NUM> and the countersinks <NUM>, <NUM> seat in the openings <NUM>, <NUM> of the ferrule support <NUM>.

Once the fastener body <NUM> has been connected to the assembly of the ferrule support <NUM>, ferrules <NUM>, and cable end portions <NUM>, the bolts <NUM>, <NUM> may be advanced through the openings <NUM>, <NUM> and <NUM>, <NUM> until the head portions seat against the upper plate <NUM>. Nuts <NUM>, <NUM> are threaded onto the shank portions <NUM> of the bolts <NUM>, <NUM> and tightened down which draws the nuts <NUM>, <NUM> against the lower plate <NUM>. Tightening down the nuts <NUM>, <NUM> unifies the fastener <NUM> and applies pressure to the belt material between the upper and lower plates <NUM>, <NUM>.

With reference to <FIG> and <FIG>, the fasteners <NUM> are shown secured to the conveyor belt ends <NUM>, <NUM> with the loops <NUM> of each of the fasteners <NUM> secured to one belt end <NUM>, <NUM> received in the recesses <NUM> of the longitudinally aligned fastener <NUM> secured to the other belt end <NUM>, <NUM>. The splice <NUM> includes longitudinal gaps <NUM> between each loop <NUM> of each fastener <NUM> secured to the conveyor belt end <NUM> and the longitudinally aligned ferrule <NUM> of the fastener <NUM> secured to the other conveyor belt end <NUM>. The loops <NUM> of the fasteners <NUM> secured to the conveyor belt end <NUM> are similarly spaced from longitudinally aligned ferrules <NUM> of the fasteners <NUM> secured to the conveyor belt end <NUM>.

With reference to <FIG>, each conveyor belt end <NUM>, <NUM> includes an upper cover portion <NUM>, an intermediate portion <NUM> that includes the cables <NUM>, and a lower cover portion <NUM>. The material of the upper and lower cover portions <NUM>, <NUM> may have different characteristics than the rubber of the intermediate portion <NUM>. For example, the upper and lower covers <NUM>, <NUM> may have enhanced resistance to chemicals and/or ultraviolet light. The conveyor belt <NUM> may contain reinforcing structures in addition to the cables <NUM>, such as fabric or textiles.

The ends <NUM>, <NUM> may be formed by cutting the conveyor belt <NUM>. The conveyor belt <NUM> and cables <NUM> therein may be cut, for example, using an angle grinder. Before applying the fasteners <NUM> to the conveyor belt ends <NUM>, <NUM>, a skiving operation is performed to remove sections of the upper and lower cover portions <NUM>, <NUM>. This leaves a skived portion <NUM> of each conveyor belt end <NUM>, <NUM>. The skived portion <NUM> of the belt ends <NUM>, <NUM> includes material of the intermediate portion <NUM> encasing the cables <NUM>.

Next, the user cleans the material of the intermediate portion <NUM> off of the cables <NUM> including the end portions <NUM> thereof. This cleaning may be performed, for example, using a tool with an oscillating blade, a hand knife with a hooked blade and/or a grinding tool with a wire brush.

The ferrules <NUM> are positioned on the now-exposed end portions <NUM> of the cables <NUM>, the ferrules <NUM> are crimped, the ferrule supports <NUM> are connected to the cables <NUM>, and the remaining components of the fastener <NUM> are assembled onto the cables <NUM> as discussed above. The skived portion <NUM> of each belt end <NUM>, <NUM> is clamped between the inboard end portions <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM> with tightening of the bolts <NUM>, <NUM>.

Each cable <NUM> includes a plurality of filaments or wires. In one embodiment, the wires are grouped together in bundles of wires with each wire extending helically in the bundle. In one embodiment, the cable <NUM> includes seven bundles of seven wires each. The seven bundles include one central bundle and six peripheral bundles in a helical arrangement around the central bundle. As the conveyor belt bends, such as going around a pulley, the wires of the cable <NUM> can slide past each other and move about each other to reduce the stress level in the strands of the cable <NUM>.

Each fastener <NUM> provides a length <NUM> of cable <NUM> engaged with the ferrule <NUM>. Each fastener <NUM> further provides a length <NUM> of each cable <NUM> extending from the ferrule <NUM> to the skived portion <NUM>. The length <NUM> may vary from cable <NUM> to cable <NUM> due to user error although such variance is not desired or intended. The sum of the lengths <NUM> and <NUM> may be in the range of <NUM> to <NUM> (two inches to three inches), such as approximately <NUM> (<NUM> inches). Further, each fastener <NUM> provides a length <NUM> of the cable <NUM> from an outboard edge <NUM> of the skived portion <NUM> to an inboard edge <NUM> of the upper and lower plates <NUM>, <NUM> at the fastener inboard portion <NUM>. The length <NUM> may be in the range of <NUM> to <NUM> (<NUM> inches to <NUM> inches), such as approximately <NUM> (one inch).

The cables <NUM> hold tension while in a bent shape such as when the splice <NUM> goes around a pulley. The individual wires of the cables <NUM> can move relative to each other to a position of lower stress which permits bending of the cables <NUM> without stress in the cables <NUM> exceeding safety limits. The action of crimping the ferrule <NUM> onto one of the cables <NUM> effectively fixes an end section of all of the wires of the cable <NUM> within the ferrule <NUM> from moving and relieving stress as the cable <NUM> bends.

It has been found that the movement of the conveyor belt <NUM> over pulleys results m the fasteners <NUM> bending the cables <NUM> generally at the inboard edges <NUM> of the upper and lower plates <NUM>, <NUM>. The bending of the cables <NUM> causes deformation in the cable <NUM> in the form of wires of the cable <NUM> sliding past each other or otherwise adjusting the positions of the wires to reduce the stress level therein. The upper and lower plates <NUM>, <NUM> are longitudinally sized to provide a distance <NUM> between the inboard the edge <NUM> of the upper and lower plates <NUM>, <NUM> and the ferrule <NUM>. The distance <NUM> provides a strain relief length <NUM> of each cable <NUM> extending longitudinally between the inboard edge <NUM> and the ferrule <NUM>. The strain relief length <NUM> provided by the upper and lower plates <NUM>, <NUM> moves the deformation in the cable <NUM> due to bending farther away from the ferrule <NUM>. This reduces fatigue of the crimped end portion <NUM> of the cable <NUM> because the deformation is occurring farther away from the crimped end portion <NUM> of the cable <NUM> at locations where the wires of the cable <NUM> can move relative to each other and relieve stress, which improves the durability of the connection between the fastener <NUM> and the cable <NUM>. Further, the skived portion <NUM> of the belt end <NUM>, <NUM> is compressed between the inboard end portions <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM>. The compressed material of the skived portion <NUM> acts as a shock absorber to accommodate the loading applied to the upper and lower plates <NUM>, <NUM> as the upper and lower plates <NUM>, <NUM> travel around pulleys.

Preferably, the components of the fastener <NUM> are of metallic materials. In one embodiment, the fastener body <NUM> is made of <NUM> stainless carbon steel, the ferrule support <NUM> is made of medium carbon steel, the ferrules <NUM> are made of copper or stainless steel, the bolts <NUM>, <NUM> are made of steel, and the nuts <NUM>, <NUM> are made of steel. Other materials for these components may be employed. The bolts <NUM>, <NUM> may take the form of a flat head screw. The hinge pin <NUM> may be a nylon-covered steel cable having braided steel wires.

In one embodiment, the fastener body <NUM>, ferrule support <NUM>, and bolts <NUM>, <NUM> are made of steel and the ferrules <NUM> are made of copper that is less rigid or is softer than the steel of the nearby components. Once the fastener <NUM> has been installed on a pair of cables <NUM>, significant tension loads are applied to the cables <NUM> which firmly engages the end portions <NUM> of the ferrules <NUM> with the ferrule support <NUM>. In some instances, the pair of ferrules <NUM> of a fastener <NUM> are positioned on the pair of cables <NUM> by an installer at different longitudinal positions along the belt <NUM> so that one ferrule <NUM> is more outboard and the other ferrule <NUM> is more inboard relative to the rubber of the belt <NUM>. This situation may occur when, for example, one of the cables <NUM> is cut shorter than the other cable <NUM> or the installer crimps the ferrules <NUM> at different longitudinal positions along the cables <NUM>.

In these longitudinally misaligned situations, the outboard ferrule <NUM> is spaced from or not fully engaged with the ferrule support <NUM> such that the cable <NUM> of the outboard ferrule <NUM> is under a significantly lower tensile load than the cable <NUM> of the inboard ferrule <NUM>. The inboard ferrule <NUM> transfers the tensile load from the associated cable <NUM> and the material of the belt surrounding the cable <NUM> of the outboard ferrule <NUM> to the ferrule support <NUM>. The higher tensile load in the cable <NUM> of the inboard ferrule <NUM> compresses the end portion <NUM> of the inboard ferrule <NUM> against the ferrule support <NUM>. The end portion <NUM> of the inboard ferrule <NUM> is therefore subjected to compressive stress due to the engagement with the ferrule support <NUM> that is greater than if both ferrules <NUM> were engaged with the ferrule support <NUM>. It is believed that the softer material of the ferrules <NUM> permits the end portion <NUM> of the inboard ferrule <NUM> to compress longitudinally and effectively take up the difference in the longitudinal positions of the ferrules <NUM> along the belt <NUM>. In other words, the high stress imparted to the inboard ferrule <NUM> shortens the ferrule <NUM> until the outboard ferrule <NUM> engages the ferrule support <NUM> and starts to transfer tensile loads from the cable <NUM> of the outboard ferrule <NUM> to the ferrule support <NUM>. In this manner, the deformation of the end portion <NUM> of the more inboard ferrule <NUM> compensates for the longitudinal misalignment of the ferrules <NUM> on the cables <NUM>. This is advantageous because too much tension in one cable <NUM> while too little tension in the other cable <NUM> can contribute to mistracking of the conveyor belt <NUM>.

With reference to <FIG>, another splice <NUM> is provided for joining ends <NUM>, <NUM> of a conveyor belt <NUM>. The splice <NUM> include fasteners <NUM> that are each connected to one of the cables <NUM> (see <FIG>) of the conveyor belt ends <NUM>, <NUM>. Regarding <FIG>, each fastener <NUM> is secured to the respective cable <NUM> and has a loop <NUM> with an opening <NUM> that receives a hinge pin <NUM> of the splice <NUM>. Each fastener <NUM> includes a hinge portion <NUM> having the loop <NUM> and a cable-receiving portion <NUM> for receiving and being secured to one of the cables <NUM>. The fastener <NUM> includes a fastener body <NUM> that may be elongated and includes a longitudinal opening, such as a blind bore <NUM>, sized to receive an end portion <NUM> of the cable <NUM> as the cable end portion <NUM> is advanced in direction <NUM> into the blind bore <NUM>. Regarding <FIG> and <FIG>, the fastener body <NUM> has a generally rectangular block-like shape that is narrower in the lateral direction than the fastener body <NUM> is tall in the vertical direction. The narrow configuration of the fastener body <NUM> permits the splice <NUM> to accommodate troughing of the conveyor belt <NUM>.

The fastener <NUM> includes a first cable locking assembly <NUM> and a second cable locking assembly <NUM> that operate laterally side-by-side to one another to secure the cable <NUM> in the blind bore <NUM>. In one embodiment, the first and second cable locking assemblies <NUM>, <NUM> each include one or more locking members, such as set screws <NUM>, received in apertures <NUM> in an upper wall portion <NUM> of the fastener body <NUM>. The set screws <NUM> have rotary drive structures <NUM> for receiving a driver, such as an Allen driver bit of a power tool, and a leading end portion <NUM> (see <FIG>) for compressing the cable <NUM> against a portion <NUM> (see <FIG>) of a surface <NUM> the bore <NUM> and capturing the cable <NUM> within the blind bore <NUM>.

With reference to <FIG>, <FIG>, and <FIG>, the upper wall of the fastener body <NUM> includes upper surfaces <NUM>, <NUM> that extend transversely to one another. With the transverse orientation of the upper surfaces <NUM>, <NUM>, the apertures <NUM> in the surfaces will extend obliquely to one another so that the set screws <NUM> therein apply a somewhat zigzag pattern of contact against the cable <NUM> as discussed in greater detail below.

With reference to <FIG> and <FIG>, the fastener body <NUM> includes a recess <NUM> so that with the fastener <NUM> secured to one belt end, the fastener recess <NUM> can receive the loop <NUM> of a longitudinally aligned fastener <NUM> secured to the other belt end. The fastener body <NUM> includes the upper wall portion <NUM> having the apertures <NUM> formed therein and a lower wall <NUM> which includes the bore surface portion <NUM> against which the cable <NUM> is compressed by the set screws <NUM>. The upper wall portion <NUM> and the lower wall portion <NUM> cooperate to form the bore <NUM> with each of the wall portions <NUM>, <NUM> having a portion of the surface <NUM> of the bore <NUM>. The fastener <NUM> includes an end wall portion <NUM> forming a closed end <NUM> of the blind bore <NUM>. The end wall portion <NUM> of the fastener body <NUM> spaces the closed end <NUM> by a distance <NUM> from the aperture 342C. The distance <NUM> permits the set screw <NUM> the aperture 342C to engage wires of the cable <NUM> spaced from the ends of the wires of the cable <NUM>, which tend to splay apart when compressed, to increase the strength of the connection between the set screw <NUM> in the aperture 342C and the cable <NUM>.

With reference to <FIG>, the fastener body <NUM> further includes a spacer portion <NUM> that extends a distance <NUM> between an aperture 342A and an inboard end <NUM> of the fastener body <NUM>. It has been observed that the cable <NUM> bends near the inboard end <NUM> of the fastener <NUM>. The distance <NUM> provided by the spacer portion <NUM> moves the stress concentration due to the bending away from the apertures 342A, 342B and the set screws <NUM> therein that engage the cable <NUM>. The distance <NUM> provides bend or strain relief by moving the bending point of the cable <NUM> away from the tightly secured bundles of wires of the cable <NUM>.

With reference to <FIG> and <FIG>, the apertures <NUM> have an alternating orientation relative to a vertical axis <NUM> of the fastener body <NUM>. More specifically, with reference to <FIG>, the aperture 342A has an inlet opening <NUM>, an outlet opening <NUM>, and a central aperture axis <NUM> extending between the inlet opening <NUM> and the outlet opening <NUM>. The fastener body <NUM> includes an aperture surface <NUM> extending about the aperture 342A and including threads for engaging the set screw <NUM>. The blind bore <NUM> has a central longitudinal axis <NUM> extending perpendicular to the vertical axis <NUM> of the fastener body <NUM>. The aperture central axis <NUM> extends at an angle <NUM> relative to the vertical axis <NUM>. Thus, as the set screw <NUM> is driven in direction <NUM> along the aperture central axis <NUM>, the set screw <NUM> compresses the cable <NUM> against the bore surface portion <NUM>.

With reference to <FIG>, the aperture 342B likewise has an aperture central axis <NUM> oriented at an angle <NUM> relative to the vertical axis <NUM> of the fastener body <NUM>. The angle <NUM> may be the same or different as the angle <NUM>. As shown in <FIG>, the set screw <NUM> is driven in direction <NUM> along the aperture central axis <NUM> to engage the cable <NUM> and compress the cable <NUM> against the bore surface portion <NUM>.

With reference to <FIG>, each set screw <NUM> includes a trailing end portion <NUM> that includes the rotary drive structure <NUM> and a body <NUM> having threads <NUM>. The leading end portion <NUM> of the set screw <NUM> includes the nose <NUM> for contacting the cable <NUM>. The nose <NUM> may have a frustoconical surface <NUM> that wedges between bundles of wires of the cable and helps secure the set screw <NUM> to the cable <NUM>. The nose <NUM> may also include a flat surface <NUM> which applies a focused, compressive force on the cable <NUM>.

With reference to <FIG>, the fasteners <NUM> are shown secured to the cables <NUM> and the loops <NUM> of fasteners <NUM> are in a laced arrangement on the hinge pin <NUM>. With reference to <FIG>, each cable <NUM> extends in the blind bore <NUM> of one of the fasteners <NUM>. The conveyor belt ends <NUM>, <NUM> each include an upper cover <NUM>, an intermediate portion <NUM> including the cables <NUM> and surrounding rubber, and a lower cover <NUM>. During installation of the fasteners <NUM> on the conveyor belt ends <NUM>, <NUM>, the material of the conveyor belt ends <NUM>, <NUM> is cleaned off of the cables <NUM> to expose the cables <NUM>. The fasteners <NUM> are slid onto the cables <NUM> and the set screws <NUM> are tightened down to secure the cables <NUM> in the fasteners <NUM>.

With reference to <FIG>, the set screws <NUM> contact the cable <NUM> in a zigzag or alternating pattern with each of the set screws <NUM> contacting the cable <NUM> generally on opposite sides of the central longitudinal axis <NUM> of the blind bore <NUM> when viewed as shown in <FIG>. Each set screw <NUM> is spaced both longitudinally and laterally from adjacent set screws <NUM> and these adjacent set screws <NUM> push the cable <NUM> down but in oblique directions generally opposite to the oblique direction of the adjacent set screws <NUM> relative to the vertical axis <NUM>.

The staggered pattern of the contact of the set screws <NUM> against the cable <NUM> positions pairs of the set screws 340C, 340D, 340E, and 340F along transverse axes <NUM>, <NUM>. The transverse axes <NUM>, <NUM> may be oblique relative to the central longitudinal axis <NUM>. The alternating positioning of the set screws <NUM> permits the set screw <NUM> to contact different bundles of wires of the cable <NUM>. Stated differently, as the bundles of wires of the cable <NUM> extend helically around the central bundle of the cable <NUM>, the different bundles will be presented to the different set screws <NUM> along the length of the blind bore <NUM>. The engagement of the set screws <NUM> with different bundles of wires of the cable <NUM> provides a mechanical lock on each bundle of wires. This provides resistance to turning of the cable <NUM> within the blind bore <NUM> in addition to the set screws <NUM> compressing the cable <NUM> against the fastener lower wall <NUM> and inhibiting pull-out of the cable <NUM> in direction <NUM>. In one embodiment, the fastener body <NUM> and the set screws <NUM> are made of one or more metallic materials such as steel.

Regarding <FIG>, a fastener <NUM> is provided that is similar in many respects to the fastener <NUM> discussed above such that differences be highlighted. The fastener <NUM> is shown secured to a portion of a conveyor belt end <NUM> having cables <NUM>, <NUM> that are embedded in a belt material <NUM> (see <FIG>) such as one or more layers of rubber. In <FIG>, the fastener <NUM> includes a connector <NUM> having a fastener body <NUM> and a stop <NUM>. In one embodiment, the stop <NUM> includes a stop body such as a ferrule support <NUM>. The fastener <NUM> includes a spacer <NUM> (see <FIG>) and one or more crimps such as ferrules <NUM>, <NUM> secured to the cables <NUM>, <NUM>. The fastener body <NUM> includes an upper member such as an inboard upper plate <NUM>, a lower member such as an inboard lower plate <NUM>, and an outboard loop portion <NUM>. The fastener body <NUM> extends from an upper inboard end portion <NUM> of the upper plate <NUM>, through one or more loops <NUM> of the outboard loop portion <NUM>, and to a lower inboard end portion <NUM> of the lower plate <NUM>.

Regarding <FIG> and <FIG>, the ferrule support <NUM> has a ferrule-facing wall <NUM> to resist movement of the ferrules <NUM>, <NUM> in pull-through direction <NUM>. The fastener body <NUM> further includes a ferrule support stop <NUM> to limit movement of the ferrule support <NUM>. The ferrule support stop <NUM> may include ridges <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM> that locally decrease the height of a gap <NUM> between the upper and lower plates <NUM>, <NUM> to be less than a height of the ferrule support <NUM>. The ferrule support stop <NUM> may also include countersinks <NUM>, <NUM> (see <FIG>) that engage recesses <NUM>, <NUM> of the ferrule support <NUM>. Regarding <FIG>, when the fastener <NUM> is secured to the conveyor belt end <NUM> and linked via a hinge pin to a fastener on an opposing conveyor belt end, the tension in the cables <NUM>, <NUM> urges the ferrules <NUM>, <NUM> against the ferrule-facing wall <NUM> of the ferrule support <NUM>. The compression of the ferrules <NUM>, <NUM> against the ferrule support <NUM> urges an inboard-facing wall <NUM> of the ferrule support <NUM> in direction <NUM> against the ridges <NUM>, <NUM> and tightly engages the ferrule support <NUM> with the countersinks <NUM>, <NUM> of the fastener body <NUM>. The assembly of the ferrules <NUM>, <NUM>, ferrule support <NUM>, and fastener body <NUM> thereby provides a rigid construct to transfer the tension in the cables <NUM>, <NUM> to the hinge pin of the splice and the associated fasteners of the opposing conveyor belt end.

With reference to <FIG>, the fastener <NUM> includes one or more attachment members, such as bolts <NUM>, <NUM>, extending apertures or through openings <NUM>, <NUM> and <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM>. The fastener <NUM> further includes nuts <NUM>, <NUM> that engage threaded portions <NUM> of the bolts <NUM>, <NUM> and keep the upper and lower plates <NUM>, <NUM> into clamped engagement with the ferrule support <NUM> and the spacer <NUM>. In other embodiments, one or more rivets or screws may be used instead of or in addition to the bolts <NUM>, <NUM> and nuts <NUM>, <NUM>.

In <FIG>, the ferrules <NUM>, <NUM> are shown in a deformed configuration and have central throughbores <NUM> that receive the cables <NUM>, <NUM> and ridges <NUM> that abut the ferrule-facing wall <NUM> of the ferrule support <NUM>. The ferrule support <NUM> is similar to the ferrule support <NUM> discussed above and includes the upper recess <NUM> that mates with the countersink <NUM> of the upper plate <NUM>. The ferrule support <NUM> has a pair of spaced apart sidewalls <NUM>, <NUM> with lower beveled surfaces thereon that form the recess <NUM> which mates with the countersink <NUM> of the lower plate <NUM>, The countersink <NUM> extends downward from an inner surface <NUM> of the upper plate <NUM> while the countersink <NUM> extends upwardly from an inner surface <NUM> of the lower plate <NUM>. The upper and lower plates <NUM>, <NUM> further include a countersink <NUM> and a countersink <NUM> that also extend inwardly from the inner surfaces <NUM>, <NUM>.

The bolts <NUM>, <NUM> each include a head portion <NUM> that is seated in one of the countersinks <NUM>, <NUM> and shank portions <NUM> that extend into the gap <NUM> between the upper and lower plates <NUM>, <NUM>. The head portion <NUM> may have a lower surface with a shape, e.g., frustoconical, that seats against an inner surface of the countersinks <NUM>, <NUM>. The head portion <NUM> likewise has a flat upper surface that is flush with or below a lower surface of the lower plate <NUM> (see <FIG>) to reduce the profile of the bolts <NUM>, <NUM> on the lower plate <NUM> and limit ingress of debris into the openings <NUM>, <NUM> of the countersinks <NUM>, <NUM>.

The countersinks <NUM>, <NUM> include anti-rotation members, such as tabs <NUM>, that extend into recesses <NUM> of head portions <NUM> of the bolts <NUM>, <NUM>. The engagement between tabs <NUM> and recesses <NUM> fixes the bolts <NUM>, <NUM> against rotation in the openings <NUM>, <NUM>. Further, the head portions <NUM> of the bolts <NUM>, <NUM> include tapered portions <NUM> that taper gradually to the threaded portion <NUM> and increase the durability of the bolts <NUM>, <NUM>.

Regarding <FIG>, the spacer <NUM> may be made of a rigid material, such as steel, to resist movement of the upper and lower plates <NUM>, <NUM> toward one another during conveyor belt operation. By describing the spacer <NUM> as rigid, it is intended that the spacer <NUM> resists compression during operation of the conveyor belt and provides a hard stop for the upper and lower plates <NUM>, <NUM>, The spacer <NUM> resists movement of the upper and lower plates <NUM>, <NUM> toward each other and the bolt <NUM> and nut <NUM> resist movement of the upper and lower plates <NUM>, <NUM> away from each other. In this manner, the spacer <NUM>, bolt <NUM>, and nut <NUM> rigidly fix the upper and lower plates <NUM>, <NUM> relative to one another, which maintains a more constant tension in the bolts <NUM>, <NUM> and prolongs the life of the bolts <NUM>, <NUM>.

The spacer <NUM> includes an upper portion <NUM>, a lower portion <NUM>, and recesses <NUM>, <NUM> of the upper and lower portions <NUM>, <NUM>. The recesses <NUM>, <NUM> receive the countersinks <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM>. The spacer <NUM> further includes mating portions, such as upper contact surfaces <NUM> and lower contact surfaces <NUM>, that are tapered to engage wall portions <NUM>, <NUM> of the countersinks <NUM>, <NUM>. The spacer <NUM> includes a throughbore <NUM> that receives the shank portion <NUM> of the bolt <NUM>. The spacer <NUM> is dogbone-shaped and the recesses <NUM>, <NUM> permit the fastener body <NUM> and countersinks <NUM>, <NUM> thereof to be slid laterally onto the spacer <NUM> as discussed below with reference to <FIG>.

Regarding <FIG>, the fastener <NUM> is secured to the conveyor belt end <NUM>. The cable <NUM> is shown extending between the upper and lower plates <NUM>, <NUM> with a cable end portion <NUM> of the cable <NUM> received in the ferrule <NUM>. The rib <NUM> of the ferrule <NUM> contacts a stop surface <NUM> of the ferrule-facing wall <NUM> of the ferrule support <NUM>. The cable <NUM> includes a plurality of wires and the cable end portion <NUM> includes end sections of the wires of the cable <NUM>. Due to the compression of the ferrule <NUM>, the end sections of the wires of cable end portion <NUM> are effectively fixed relative to one another and may not shift about and along each other to facilitate bending of the cable <NUM>.

The upper and lower plates <NUM>, <NUM> include longitudinal spacer portions <NUM>, <NUM> that separate the ferrules <NUM> and cable end portions <NUM> therein a distance <NUM> from ends <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM>. Regarding cable <NUM>, the distance <NUM> provides a predetermined length <NUM> of the cable <NUM> within the fastener <NUM>. Further, the distance <NUM> provides a strain relief length <NUM> of the cable <NUM> extending longitudinally between the ends <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM> of the fastener body <NUM> to the ferrule <NUM>. The sections of the wires of the cable <NUM> along the strain relief length <NUM> may shift about and along each other with bending of the cable <NUM> to relieve stress, which increases the durability of the connection between the fastener <NUM> and the cable <NUM>. In some embodiments, a portion of the strain relief length <NUM> of each cable <NUM>, <NUM> within the fastener <NUM> is embedded with belt material <NUM>.

Regarding <FIG>, the upper and lower plates <NUM>, <NUM> are shown clamped onto the spacer <NUM> by the bolts <NUM>, <NUM> and nuts <NUM>, <NUM>. The countersinks <NUM>, <NUM> are engaged with the upper portion <NUM> and lower portion <NUM> of the spacer <NUM>. Specifically, the wall portions <NUM>, <NUM> abut the upper and lower contact surfaces <NUM>, <NUM> of the spacer <NUM>. The assembly of the nut <NUM> and the bolt <NUM> resists separation of the upper and lower plate portions <NUM>, <NUM> in directions <NUM>, <NUM> while the presence of the spacer <NUM> resists movement of the upper and lower plate portions <NUM>, <NUM> toward one another in directions <NUM>, <NUM>. In this manner, the upper and lower plate portions <NUM>, <NUM> have a fixed distance <NUM> between the inner surfaces <NUM>, <NUM> (see <FIG>) at the upper and lower inboard end portions <NUM>, <NUM>. The presence of the spacer <NUM> provides a rigid stop for the upper and lower plate portions <NUM>, <NUM> that limits movement of the plate portions <NUM>, <NUM> toward each other, followed by rebounding apart, which may create spikes in the tension of the bolts <NUM>, <NUM>. The spacer <NUM> maintains the distance between the upper and lower plate portions <NUM>, <NUM> to provide a more constant tensile load on the bolts <NUM>, <NUM>, which may improve the lifespan of the bolts <NUM>, <NUM>.

Regarding <FIG>, a method of connecting portions of the fastener <NUM> to the conveyor belt end <NUM> is disclosed. The method includes preparing the conveyor belt end <NUM> to have a tongue or skived portion <NUM> and trimming the belt material <NUM> to expose the cables <NUM>, <NUM>. The skived portion <NUM> includes upper and lower surfaces <NUM>, <NUM> of the conveyor belt end <NUM>. The trimming also includes forming a gap <NUM> in the belt material <NUM> that separates portions <NUM>, <NUM> of the belt material <NUM>. The ferrules <NUM>, <NUM> are applied to the end portions <NUM> of the cables <NUM>, <NUM> as discussed above. The ferrule support <NUM> is advanced downwardly in direction <NUM> onto the cables <NUM> and the spacer <NUM> is fit m direction <NUM> into the gap <NUM>. In <FIG>, the spacer <NUM> is held between the portions <NUM>, <NUM> of the conveyor belt material <NUM> embedding the cables <NUM>, <NUM>. In another embodiment, the belt material <NUM> may be completely removed on each side of the spacer <NUM>.

Regarding <FIG> and <FIG>, the cables <NUM>, <NUM> extend along opposite sides of the spacer <NUM>, through the through openings <NUM>, <NUM> of the ferrule support <NUM>, and into the throughbores <NUM> of the ferrules <NUM>, <NUM>. With the spacer <NUM>, ferrule support <NUM>, and ferrules <NUM>, <NUM> positioned on the cables <NUM>, <NUM>, the fastener body <NUM> may then be advanced laterally in direction <NUM> so that the upper and lower plates <NUM>, <NUM> sandwich the spacer <NUM> and ferrule support <NUM> therebetween.

Regarding <FIG> and <FIG>, the countersinks <NUM>, <NUM> of the fastener body <NUM> mate with the corresponding recesses <NUM>, <NUM> of the ferrule support <NUM> and the countersinks <NUM>, <NUM> mate with the recesses <NUM>, <NUM> of the spacer <NUM>. In this configuration, the openings <NUM>, <NUM> are aligned with the throughbore <NUM> of the spacer <NUM> and the openings <NUM>, <NUM> are aligned with the through opening <NUM> of the ferrule support <NUM>. The bolts <NUM>, <NUM> may be advanced through the aligned openings of the fastener body <NUM>, spacer <NUM>, and ferrule support <NUM> and the nuts <NUM>, <NUM> tightened onto the threaded shank portions <NUM> of the bolts <NUM>, <NUM>. The fastener <NUM> is thereby secured to the conveyor belt end <NUM>. In one embodiment, the bolts <NUM>, <NUM> have a length larger than the height of the fastener body <NUM>. Once the nuts <NUM>, <NUM> have been tightened down onto bolts <NUM>, <NUM>, the excess lengths of the bolts <NUM>, <NUM> projecting beyond the upper plate <NUM> are removed using a bolt breaker. This positions the ends of the bolt shank portions <NUM> flush with or below an upper surface of the upper plate <NUM>.

Regarding <FIG>, a support <NUM> is provided that includes a body <NUM> having a ferrule support portion <NUM> and a spacer portion <NUM>. The body <NUM> has a unitary, one-piece construction and may be made of a metallic material, such as steel. The ferrule support portion <NUM> and spacer portion <NUM> provide similar operability as the ferrule support <NUM> and the spacer <NUM> discussed above such that the support <NUM> may be utilized in the fastener <NUM> in place of the ferrule support <NUM> and spacer <NUM>. Because the support <NUM> has a one-piece construction, the support <NUM> may readily positioned on and supported by the cables <NUM>, <NUM> even if the belt material <NUM> has been trimmed so that there are no belt material portions <NUM>, <NUM> on the cables <NUM>, <NUM>.

The support <NUM> includes through openings <NUM>, <NUM> for receiving the cables <NUM>, <NUM> and a lower opening <NUM> that permits the support <NUM> to be advanced downwardly onto the cables <NUM>, <NUM>. The support <NUM> includes a ferrule-facing wall <NUM> against which the ferrules <NUM>, <NUM> may abut and an outboard facing wall <NUM>. The support <NUM> includes an upper wall <NUM> and depending side walls <NUM>, <NUM>. The upper wall <NUM> includes upper recesses <NUM>, <NUM> for receiving, respectively, countersinks <NUM>, <NUM> of the upper plate <NUM> of the fastener body <NUM>. The side walls <NUM>, <NUM> includes lower beveled surfaces <NUM>, <NUM> (see <FIG>) configured to form mating engagements with the outer surfaces of the countersinks <NUM>, <NUM>. The upper wall <NUM> also includes through openings <NUM>, <NUM> that permit the bolts <NUM>, <NUM> to extend therethrough and connect the upper and lower plates <NUM>, <NUM> of the fastener body <NUM>. To fix the support <NUM> within the fastener body <NUM>. the support <NUM> includes grooves <NUM>, <NUM> that mate with the ridges <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM>.

Regarding <FIG>, the side walls <NUM>, <NUM> include ledge portions <NUM>, <NUM> having the beveled surfaces <NUM>, <NUM> thereon. The support <NUM> includes a saddle portion <NUM> that extends between the cables received in the through openings <NUM>, <NUM>. The saddle portion <NUM> and side walls <NUM>, <NUM> cooperate to form a loose slip fit between the support <NUM> and the cables <NUM>, <NUM> during installation of the fastener <NUM> on the cables <NUM>, <NUM>. Once the fastener <NUM> has been secured to the cables <NUM>, <NUM>, the saddle portion <NUM> and side walls <NUM>, <NUM> are configured to be spaced from the cables <NUM>, <NUM>. To provide clearance for the cables <NUM>, <NUM> and accommodate bending of the cables, the support <NUM> includes flared surfaces <NUM> extending about the through openings <NUM>, <NUM> near the outboard facing wall <NUM>. The flared surfaces <NUM> provide clearance for the cables <NUM>, <NUM> to limit contact between the cables <NUM>, <NUM> and the support <NUM> near the outboard facing surface <NUM>. Regarding <FIG>, the saddle portion <NUM> may also narrow as the saddle portion <NUM> nears the outboard facing wall <NUM>. The narrowing of the saddle portion <NUM> provides further clearance for movement of the cables <NUM>, <NUM>.

With reference to <FIG>, a support <NUM> is provided that includes a body <NUM> having a spacer portion <NUM> and a ferrule support portion <NUM>. The body <NUM> has a unitary, one-piece construction and may be made of a metallic material, such as steel. The spacer portion <NUM> operates similarly to the spacer <NUM> discussed above and the ferrule support portion <NUM> operates similarly to the ferrule support <NUM> discussed above. The support <NUM> has a connecting portion <NUM> joining the spacer portion <NUM> and the ferrule support portion <NUM>. The spacer portion <NUM> includes a throughbore <NUM> for receiving the bolt <NUM> and the ferrule support portion <NUM> includes a through opening <NUM> to receive the bolt <NUM>,.

Regarding <FIG>, the spacer portion <NUM> includes recesses <NUM>, <NUM> that receive the countersinks <NUM>, <NUM> and contact surfaces <NUM>, <NUM> that engage the countersinks <NUM>, <NUM> and provide a rigid stop for the upper and lower plates <NUM>, <NUM>. At the other end of the support <NUM>, the ferrule support portion <NUM> includes a ferrule-facing wall <NUM> for abutting the ferrules <NUM>, <NUM> and an inboard facing wall <NUM> for contacting the ridges <NUM>, <NUM> of the upper and lower plates <NUM>, <NUM>. In one embodiment, the connecting portion <NUM> includes a recess <NUM> that receives the ridge <NUM> and a recess <NUM> that receives the ridge <NUM>.

Claim 1:
A fastener (<NUM>, <NUM>) for securing to a conveyor belt end (<NUM>, <NUM>) having a cable (<NUM>, <NUM>, <NUM>), the fastener comprising:
a crimp (<NUM>, <NUM>, <NUM>) configured to be fixed to the cable;
a fastener body (<NUM>, <NUM>) including a longitudinally extending upper plate portion (<NUM>, <NUM>), a longitudinally extending lower plate portion (<NUM>, <NUM>), and a loop portion (<NUM>, <NUM>) connecting the upper and lower plate portions;
apertures (<NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>) of the upper and lower plate portions;
a stop body (<NUM>, <NUM>, <NUM>, <NUM>) configured to fit between the upper and lower plate portions of the fastener body and abut the crimp with the crimp longitudinally intermediate the stop body and the loop portion; and
an attachment member (<NUM>, <NUM>, <NUM>, <NUM>) configured to extend through the apertures of the upper and lower plate portions and clamp the upper and lower plate portions to the stop body so that the upper and lower plate portions resist movement of the stop body.