CA2464499A1 - Low cost food processing belts and other conveyances manufactured from conductive loaded resin-based materials - Google Patents

Abstract

Conveyors, chutes, skids, guides, and ways for the transporting of material are formed of a conductive loaded resin-based material such that fragments of these structures can be detected by a metal detector. The conductive loaded resin-based material comprises micron conductive powder(s), conductive fiber(s), or a combination of conductive powder and conductive fibers in a base resin host. The ratio of the weight of the conductive powder(s), conductive fiber(s), or a combination of conductive powder and conductive fibers to the weight of the base resin host is between about 0.20 and 0.40. The micron conductive powders are formed from non-metals, such as carbon, graphite, that may also be metallic plated, or the like, or from metals such as stainless steel, nickel, copper, silver, that may also be metallic plated, or the like, or from a combination of non-metal, plated, or in combination with, metal powders. The micron conductor fibers preferably are of nickel plated carbon fiber, stainless steel fiber, copper fiber, silver fiber, or the like. The conductive loaded resin-based structures can be formed using methods such as injection molding compression molding or extrusion. The conductive loaded resin-based material used to form structures can also be in the form of a thin flexible woven fabric that can readily be cut to the desired shape.

Description

LOW COST FOOD PROCESSING BELTS AND OTHER CONVEYANCES
MANUFACTURED FROM CONDUCTIVE LOADED RESIN-BASED MATERIALS
This Patent Application claims priority to the U.S.
Provisional Patent Application 60/462,891, filed on April 15, 2003, and to the U.S. Provisional Patent Application 60/484,400, filed on July 2, 2003, which are herein incorporated by reference in their entirety.
This Patent Application is a Continuation-in-Part of INTO1-002CIP, filed as US Patent Application serial number 10/309,429, filed on Dec. 4, 2002, also incorporated by reference in its entirety, which is a Continuation-in-Part application of docket number INTOl-002, filed as US Patent Application serial number 10/075,778, filed on Feb. 14, 2002, which claimed priority to US
Provisional Patent Applications serial number 60/317,808, filed on September 7, 2001, serial number 60/269,414, filed on Feb.
16, 2001, and serial number 60/317,808, filed on February 15, 2001.
BACKGROUND OF THE INVENTION
(1) Field of the Invention This invention relates to conveyor belts and, more particularly, to food processing belts and other conveyances molded of conductive loaded resin-based materials comprising micron conductive powders, micron conductive fibers, or a combination thereof, homogenized within a base resin when molded.

(2) Description of the Prior Art Conveyors, chutes, skids, guides, and ways for the transporting of material and articles of manufacturing are well known in the art. In the food processing industry, conveyors are used for warming and cooling food products, slicing and bagging, in-feed and discharge. The conveyor belts are generally constructed of a plastic resin such as Polypropylene, Polyethylene, Acetal, or the like, or may be constructed of a metal wire frame with an over-molded plastic resin. The conveyor belts allow processed material to be transported while remaining level and flat. Conveyors, chutes, skids, guides, and ways may be fabricated to be electrically conductive to dissipate static electricity, may be heat resistant for use in high temperature processing of food, may be moisture tolerant for wet environments, may be impact resistant to prevent breakage of glass food packaging, and may be flame retardant to prevent sustaining a flame.
A problem that may occur with plastic resin belts or with metal wire frame belts that are covered in plastic resin is wear-out induced contamination. As the plastic resin material wears out, particulate material from the plastic resin may brake away from the belt. As a result, it is possible for this material to contaminate a food item being processed on the belt.
This contamination is undesirable both in terms of food safety and of consumer acceptance.
Several prior art inventions relate to Conveyors, chutes, skids, guides, and ways and to items comprising conductive plastics. U.S. Patent 6,368,704 to Murata, et al provides a conductive paste that exhibits a high thermal conductivity (a low thermal resistance) after adhesion and hardening that enables an adhesive layer to be thinly formed and provides an electronic part that has an excellent radiating capability that enables the film's thickness to be reduced. U.S. Patent 6,277,303 to Foulger describes conductive polymer composite materials. The conductive polymer composite material includes a minor phase material that has a semicrystalline polymer. The composite material further includes a conductive filler material dispersed in the minor phase material in an amount sufficient to be equal to or greater than an amount required to generate a continuous conductive network within the minor phase material.
U.S. Patent 4,197,218 to McKaveney describes electrically conductive articles. The articles are formed of a non-conductive matrix containing an electrically conductive dispersion of finely divided ferroalloy, silicon alloy, or mixtures. U. S. Patent 6,602,446 to Ushijima provides an electrically conductive paste made up of an electrically conductive filler and a conveyor belt adapted to generate heat by electromagnetic induction are compounded with a resin.
INTRALOX Inc. USA, 201 Laitram Lane, Harahan, Louisiana 70123, Ammeraal Beltech, 75011 N. St. Louis Ave., Skokie, Il 60076, and Siegling America, Inc., 12201 Vanstory Road, Huntersville, NC 28078 are manufacturers of conveyor belting.
Each manufacturer describes conductive belting manufactured of plastic resins with embedded conductors. Cassel Messtechnik GmbH, Carl-Giesecke-Str. 3, 37079 Gottingen, Germany manufactures a metal detector for the food industry. The metal detector operates on the basis of an inductive measuring principle. A high-frequency electromagnetic alternating field is generated by a transmitter coil. If a metal piece passes through the metal detector, the field experiences a change corresponding to the magnetic and electrical properties of the metal piece. In the article by McCluskey, et al., "Nanocomposite Materials Offer Higher Conductivity and Flexibility", Proceedings of 3rd International Conference on Adhesive Joining and Coating Technology in Electronics Manufacturing, 1998, pp: 282-286, the mechanical and electrical characteristics of a conductive polymer made with conductive silver flake nanoparticle fillers is described. In the article by Fan et al., "Fundamental Understanding of Conductivity Establishment for Electrically Conductive Adhesives," Proceedings of the 52nd Electronic Components and Technology Conference, 2002, pp: 1154- 1157, several epoxy resin based curing systems are described.
SUMMARY OF THE INVENTION
A principal object of the present invention is to provide effective food processing belts and other conveyances.
A further object of the present invention is to provide a method to form food processing belts and other conveyances.
A further object of the present invention is to provide a food processing belts and other conveyances that are detectable by typical metal detection devices.

A yet further object of the present invention is to provide a food processing belts and other conveyances molded of conductive loaded resin-based material where the belt characteristics can be altered or the visual characteristics can be altered by forming a metal layer over the conductive loaded resin-based material.
A yet further object of the present invention is to provide methods to fabricate food processing belts and other conveyances from a conductive loaded resin-based material incorporating various forms of the material.
A yet further object of the present invention is to provide a method to fabricate food processing belts and other conveyances from a conductive loaded resin-based material where the material is in the form of a fabric.
In accordance with the objects of this invention, a conveying belt device is achieved. The device comprises a loop structure of a conductive loaded, resin-based material comprising conductive materials in a base resin host. The belt or fragments of the belt are detectable by a metal detection device.

Also in accordance with the objects of this invention, a food processing conveying apparatus is achieved. The apparatus comprises a belt of a conductive loaded, resin-based material comprising conductive materials in a base resin host. A metal detector is included such that the belt or fragments of the belt are detectable by the metal detection device.
Also in accordance with the objects of this invention, a method to form a conveying belt device is achieved. The method comprises providing a conductive loaded, resin-based material comprising conductive materials in a resin-based host. The conductive loaded, resin-based material is molded into a conveying belt device comprising a loop structure of a conductive loaded, resin-based material comprising conductive materials in a base resin host. The conveying belt or fragments of the conveying belt are detectable by a metal detection device.
BRIEF DESCRIPTION OF THE DRAWINGS
In the accompanying drawings forming a material part of this description, there is shown:

Figs. la and lb illustrate a first preferred embodiment of the present invention showing a food processing line with belts and other conveyances comprising conductive loaded resin-based material.
Fig. 2 illustrates a first preferred embodiment of a conductive loaded resin-based material wherein the conductive materials comprise a powder.
Fig. 3 illustrates a second preferred embodiment of a conductive loaded resin-based material wherein the conductive materials comprise micron conductive fibers.
Fig. 4 illustrates a third preferred embodiment of a conductive loaded resin-based material wherein the conductive materials comprise both conductive powder and micron conductive (fibers.
Figs. 5a and 5b illustrate a fourth preferred embodiment wherein conductive fabric-like materials are formed from the conductive loaded resin-based material.
Figs. 6a and 6b-illustrate, in simplified schematic form, an injection molding apparatus and an extrusion molding apparatus that may be used to mold food processing belts and other conveyances of a conductive loaded resin-based material.
Fig. 7 illustrates a second preferred embodiment of the present invention further showing a conductive loaded resin-based food processing belt with positive drive.
Fig. 8 illustrates a third preferred embodiment of the present invention further showing a conductive loaded resin-based food processing belt with friction rolling drive.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention relates to food processing belts and other conveyances molded of conductive loaded resin-based materials comprising micron conductive powders, micron conductive fibers, or a combination thereof, homogenized within a base resin when molded.
The conductive loaded resin-based materials of the invention are base resins loaded with conductive materials, which then makes any base resin a conductor rather than an insulator. The resins provide the structural integrity to the molded part. The micron conductive fibers, micron conductive powders, or a combination thereof, are homogenized within the resin during the molding process, providing the electrical continuity.
The conductive loaded resin-based materials can be molded, extruded or the like to provide almost any desired shape or size. The molded conductive loaded resin-based materials can also be cut, stamped, or vacuumed formed from an injection molded or extruded sheet or bar stock, over-molded, laminated, milled or the like to provide the desired shape and size. The thermal or electrical conductivity characteristics of food processing belts and other conveyances fabricated using conductive loaded resin-based materials depend on the composition of the conductive loaded resin-based materials, of which the loading or doping parameters can be adjusted, to aid in achieving the desired structural, electrical or other physical characteristics of the material. The selected materials used to fabricate the food processing belts and other conveyances devices are homogenized together using molding techniques and or methods such as injection molding, over-molding, thermo-set, protrusion, extrusion, calendaring, or the like. Characteristics related to 2D, 3D, 4D, and 5D designs, molding and electrical characteristics, include the physical and l0 electrical advantages that can be achieved during the molding process of the actual parts and the polymer physics associated within the conductive networks within the molded parts) or formed material(s).
The use of conductive loaded resin-based materials in the fabrication of food processing belts and other conveyances significantly lowers the cost of materials and the design and manufacturing processes used to hold ease of close tolerances, by forming these materials into desired shapes and sizes. The food processing belts and other conveyances can be manufactured into infinite shapes and sizes using conventional forming methods such as injection molding, over-molding, or extrusion, calendaring, or the like. The conductive loaded resin-based materials, when molded, typically but not exclusively produce a desirable usable range of resistivity from between about 5 and 25 ohms per square, but other resistivities can be achieved by varying the doping parameters and/or resin selection(s).
The conductive loaded resin-based materials comprise micron conductive powders, micron conductive fibers, or in any combination thereof, which are homogenized together within the base resin, during the molding process, yielding an easy to produce low cost, electrically conductive, close tolerance manufactured part or circuit. The micron conductive powders can be of carbons, graphites, amines or the like, and/or of metal powders such as nickel, copper, silver, or plated or the like.
The use of carbons or other forms of powders such as graphite(s) etc. can create additional low level electron exchange and, when used in combination with micron conductive fibers, creates a micron filler element within the micron conductive network of fibers) producing further electrical conductivity as well as acting as a lubricant for the molding equipment. The micron conductive fibers can be nickel plated carbon fiber, stainless steel fiber, copper fiber, silver fiber, or the like, or combinations thereof. The structural material is a material such as any polymer resin. Structural material can be, here given as examples and not as an exhaustive list, polymer resins produced by GE PLASTICS, Pittsfield, MA, a range of other plastics produced by GE PLASTICS, Pittsfield, MA, a range of other plastics produced by other manufacturers, silicones produced by GE SILICONES, Waterford, NY, or other flexible resin-based rubber compounds produced by other manufacturers.
The resin-based structural material loaded with micron conductive powders, micron conductive fibers, or in combination thereof can be molded, using conventional molding methods such as injection molding or over-molding or extrusion or calendaring to create desired shapes and sizes. The molded conductive loaded resin-based materials can also be stamped, cut or milled as desired to form create the desired shape form factors) of the heat sinks. The doping composition and directionality associated with the micron conductors within the loaded base resins can affect the electrical and structural characteristics of the food processing belts and other conveyances and can be precisely controlled by mold designs, gating and or protrusion designs) and or during the molding process itself. In addition, the resin base can be selected to obtain the desired thermal characteristics such as very high melting point or specific thermal conductivity.
A resin-based sandwich laminate could also be fabricated with random or continuous webbed micron stainless steel fibers or other conductive fibers, forming a cloth like material. The webbed conductive fiber can be laminated or the like to materials such as Teflon, Polyesters, or any resin-based flexible or solid material(s), which when discretely designed in fiber content(s), orientations) and shape(s), will produce a very highly conductive flexible cloth-like material. Such a cloth-like material could also be used in forming food processing belts and other conveyances. When using conductive fibers as a webbed conductor as part of a laminate or cloth-like material, the fibers may have diameters of between about 3 and 12 microns, typically between about 8 and 12 microns or in the range of about 10 microns, with lengths) that can be seamless or overlapping.
The conductive loaded resin-based material of the present invention can be made resistant to corrosion and/or metal electrolysis by selecting micron conductive fiber and/or micron conductive powder and base resin that are resistant to corrosion and/or metal electrolysis. For example, if a corrosion/electrolysis resistant base resin is combined with stainless steel fiber and carbon fiber/powder, then a corrosion and/or metal electrolysis resistant conductive loaded resin-based material is achieved. Another additional and important feature of the present invention is that the conductive loaded resin-based material of the present invention may be made flame retardant. Selection of a flame-retardant (FR) base resin material allows the resulting product to exhibit flame retardant capability. This is especially important in food processing belts and other conveyances applications as described herein.
The homogeneous mixing of micron conductive fiber and/or micron conductive powder and base resin described in the present invention may also be described as doping. That is, the homogeneous mixing converts the typically non-conductive base resin material into a conductive material. This process is analogous to the doping process whereby a semiconductor material, such as silicon, can be converted into a conductive material through the introduction of donor/acceptor ions as is well known in the art of semiconductor devices. Therefore, the present invention uses the term doping to mean converting a typically non-conductive base resin material into a conductive material through the homogeneous mixing of micron conductive fiber and/or micron conductive powder into a base resin.
As an additional and important feature of the present invention, the molded conductor loaded resin-based material exhibits excellent thermal dissipation characteristics.
Therefore, food processing belts and other conveyances manufactured from the molded conductor loaded resin-based material can provide added thermal dissipation capabilities to the application. For example, heat can be dissipated from electrical devices physically and/or electrically connected to food processing belts and other conveyances of the present invention.
Another important feature of the present invention is that the conductive loaded resin-based material is capable of compliance to FDA regulations for use in food processing and packaging applications, USDA-FSIS regulations for meat and poultry processing, and USDA regulations for dairy processing.
In particular, stainless steel, which is used herein as a conductive loading material, is approved by the FDA for use in food processing conveyances.
Referring now to Figs. la and lb, a first preferred embodiment of the present invention is illustrated. Several important features of the present invention are shown and discussed below. Referring now to Figs. la and lb, a conveyor system 10 for food processing is shown. Several components typical to a food processing conveyor system are depicted.
First, the conveyor system 10 comprises a conveyor belt 12 that is constructed of conductive loaded resin-based material according to the present invention. The conveyor belt 12 may comprise a series of linked sections as is depicted in Fig. 7 or may comprise a continuous belt of material as is illustrated in Fig. 8. Referring again to Figs. la and 1b, the conveyor system may further comprises chutes 16 and 18, skids, or other ways of transporting the food items along the processing path. In the preferred embodiment, all or part of these items 16 and 18 also comprise conductive loaded resin-based material according to the present invention. A motor, not.shown, is coupled to the sprockets or rollers 20 of the conveyor 10. As the sprockets or rollers 20 are turned by the motor, the belt 12 is pulled in a continuous loop structure. In turn, the moving belt 12 causes in process food items placed onto the belt 12 to be propelled forward through the processing flow of operations such as warming or cooling of the food products 14 or slicing and packaging of the food products 14 or the like.
During processing operations and/or as a result of normal wearing, occasionally a fragment of a conveyor belt 12 may break away from the conveyor belt 12. Typically, such fragments will fall to the floor where they can be removed by normal cleaning operations. However, on occasion, these fragments may contaminate the food product 14. It is critical to the food processor that any such contaminated food product 14 be detected and removed from the processing apparatus 10 prior to packaging 28 and shipping product to consumers. As a particularly important feature of the present invention, the conductive loaded material of the conductive loaded resin-based material comprises conductive material, such as metal, that is detectable in a metal detection device 22. Metal detection devices 22 are well known in that art as recited above. Further, the homogeneous blending of the conductive material into the base resin during the molding process insures that any fragments that break away from the belt 12 will contain detectable metallic content. Therefore, in the preferred embodiment apparatus 10, the food items 14 are caused to pass through a metal detector device 22 prior to final packaging 28. The conveying apparatus at the metal detector 22 preferably comprises a belt 26 with no metallic content so that the metal detector 22 will trigger based only on the food item 14 and any contaminants that are traveling down the conveyor with food item 14. If the metal detector 22 detects metal content in the food item 14, then a sorting mechanism 24 is used to divert the food item 14 and its contamination from the final packaging 28. The use of the novel conductive loaded resin-based belt allows the metal detector to detect and to remove the contamination caused by belt wearing and breakage. Additional, the conductive loaded resin-based material of the belt 12, and of any other conveyance item 16 and 18 in the apparatus 10, can be grounded to provide electrostatic discharge protection. As an additional feature, while maintaining metal detection capability, the belt 12 will possess excellent corrosion and electrolysis resistance. Finally, the conductive loaded resin-based material is an excellent thermal conductor in assisting in rapid thermal transfer to and from the food product during the process.

Referring now to Fig. 7 a second preferred embodiment 100 of the present invention is illustrated. A conductive loaded resin-based food processing belt with positive drive apparatus is illustrated. This conveying system 100 shown comprises a segmented belt 104. This segmented belt comprises a plurality of molded conductive loaded resin-based segments 104 that are interconnected by pivoting or pinned joints. The segments 104 are shaped to interlock or couple to a toothed sprocket 108.
This positive drive apparatus 100 is similar to a bicycle drive mechanism and provides a non-slipping propulsion of the conveying belt 104. Preferably, the conductive loaded resin-based material is injection molded to produce a plurality of segments 104 which are then coupled together to form the belt.
Alternatively, the conductive loaded resin-based material may be extrusion molded to produce a very wide piece bearing the segmental cross section. This piece can then be cut into segments 104 of desired width. As an additional, though optional feature of this embodiment, the sprocket 108 may comprise conductive loaded resin-based material. This conductive loaded resin-based material may be injection molded to form the sprocket 108. As an additional, though optional feature, each segment 104 may further comprise a metal hinge that is embedded into or molded into the molded conductive loaded resin-based material.

Referring now to Fig. 8, a third preferred embodiment of the present invention is illustrated. In this case, a continuous belt 124 of conductive loaded resin-based material. is formed.
The belt 124 is propelled using a friction rolling drive 128. In this case, a rotating roller 128 is held in position against the belt 124. More preferably, a tensioning mechanism insures that the roller 128 presses against the belt 124 to thereby create sufficient frictional coupling between roller 128 and belt 124.
The belt 124 may be formed by extrusion molding a flexible conductive loaded resin-based material into a sheet or strip, and then joining the ends of a long section of the material to form a belt. To derive a flexible material, the base resin should be one that remains flexible at the operating temperature after molding. The ends may be bound together by, for example, ultrasonic welding. As another alternative, a calendaring method may be used to homogeneously mix the conductive loaded material into the resin-base material prior to molding and curing.
Alternatively, the conductive loaded resin-based material may be formed into fabric-like material as is described below and is illustrated in Figs. 5a and 5b. This fabric-like material has high strength and maintains the metal detection capability.
This fabric-like material may be easily stacked or laminated onto other materials and may be bonded to itself to complete the belt using, for example, ultrasonic welding.
As another alternative, a metal layer, not shown, may be formed on the conveying belt or any other conveying structure comprising the conductive loaded resin-based material described herein. The belt characteristics can be altered or the visual characteristics can be altered by forming a metal layer over the conductive loaded resin-based material. If used, the metal layer may be formed by plating or by coating. If the method of formation is metal plating, then the resin-based structural material of the conductive loaded, resin-based material is one that can be metal plated. There are very many of the polymer resins that can be plated with metal layers. For example, GE
Plastics, SUPEC, VALOX, ULTEM, CYCOLAC, UGIKR.AL, STYRON, CYCOLOY
are a few resin-based materials that can be metal plated. The metal layer may be formed by, for example, electroplating or physical vapor deposition.
Other food conveyance structures, such as the chutes or guides 16 and 18 illustrated in Figs. la and lb, can easily be molded from the conductive loaded resin-based material. In this way, any material loss due to wear and/or breakage will be detectable by a metal detection device.

The conductive loaded resin-based material typically comprises a micron powders) of conductor particles and/or in combination of micron fibers) homogenized within a base resin host. Fig. 2 shows cross section view of an example of conductor loaded resin-based material 32 having powder of conductor particles 34 in a base resin host 30. In this example the diameter D of the conductor particles 34 in the powder is between about 3 and 12 microns.
Fig. 3 shows a cross section view of an example of conductor loaded resin-based material 36 having conductor fibers 38 in a base resin host 30. The conductor fibers 38 have a diameter of between about 3 and 12 microns, typically in the range of 10 microns or between about 8 and 12 microns, and a length of between about 2 and 14 millimeters. The conductors used for these conductor particles 34 or conductor fibers 38 can be stainless steel, nickel, copper, silver, or other suitable metals or conductive fibers, or combinations thereof. These conductor particles and or fibers are homogenized within a base resin. As previously mentioned, the conductive loaded resin-based materials have a resistivity between about 5 and 25 ohms per square, other resistivities can be achieved by varying the doping parameters and/or resin selection. To realize this resistivity the ratio of the weight of the conductor material, in this example the conductor particles 34 or conductor fibers 38, to the weight of the base resin host 30 is between about 0.20 and 0.40, and is preferably about 0.30. Stainless Steel Fiber of 8-11 micron in diameter and lengths of 4-6 mm with a fiber weight to base resin weight ratio of 0.30 will produce a very highly conductive parameter, efficient within any EMF
spectrum. Referring now to Fig. 4, another preferred embodiment of the present invention is illustrated where the conductive materials comprise a combination of both conductive powders 34 and micron conductive fibers 38 homogenized together within the resin base 30 during a molding process.
Referring now to Figs. 5a and 5b, a preferred composition of the conductive loaded, resin-based material is illustrated.
The conductive loaded resin-based material can be formed into fibers or textiles that are then woven or webbed into a conductive fabric. The conductive loaded resin-based material is formed in strands that can be woven as shown. Fig. 5a shows a conductive fabric 42 where the fibers are woven together in a two-dimensional weave 46 and 50 of fibers or textiles. Fig. 5b shows a conductive fabric 42' where the fibers are formed in a webbed arrangement. In the webbed arrangement, one or more continuous strands of the conductive fiber are nested in a random fashion. The resulting conductive fabrics or textiles 42, see Fig. 5a, and 42', see Fig. 5b, can be made very thin, thick, rigid, flexible or in solid form(s).
Similarly, a conductive, but cloth-like, material can be formed using woven or webbed micron stainless steel fibers, or other micron conductive fibers. These woven or webbed conductive cloths could also be sandwich laminated to one or more layers of materials such as Polyester(s), Teflon(s), Kevlar(s) or any other desired resin-based material(s). This conductive fabric may then be cut into desired shapes and sizes.
Food processing belts and other conveyances formed from conductive loaded resin-based materials can be formed or molded in a number of different ways including injection molding, extrusion or chemically induced molding or forming. Fig. 6a shows a simplified schematic diagram of an injection mold showing a lower portion 54 and upper portion 58 of the mold 50.
Conductive loaded blended resin-based material is injected into the mold cavity 64 through an injection opening 60 and then the homogenized conductive material cures by thermal reaction. The upper portion 58 and lower portion 54 of the mold are then separated or parted and the food processing belts or other conveyances is removed.

Fig. 6b shows a simplified schematic diagram of an extruder 70 for forming food processing belts and other conveyances using extrusion. Conductive loaded resin-based materials) is placed in the hopper 80 of the extrusion unit 74. A piston, screw, press or other means 78 is then used to force the thermally molten or a chemically induced curing conductive loaded resin-based material through an extrusion opening 82 which shapes the thermally molten curing or chemically induced cured conductive loaded resin-based material to the desired shape. The conductive loaded resin-based material is then fully cured by chemical reaction or thermal reaction to a hardened or pliable state and is ready for use.
The advantages of the present invention may now be summarized. Effective food processing belts and other conveyances are achieved. Methods to form food processing belts and other conveyances are achieved. Food processing belts and other conveyances that are detectable by typical metal detection devices are achieved. The belt characteristics can be altered or the visual characteristics can be altered by forming a metal layer over the conductive loaded resin-based material.
Methods to fabricate food processing belts and other conveyances from a conductive loaded resin-based material incorporating various forms of the material are achieved. A method to fabricate food processing belts and other conveyances from a conductive loaded resin-based material where the material is in the form of a fabric is achieved.
As shown in the preferred embodiments, the novel methods and devices of the present invention provide an effective and manufacturable alternative to the prior art.
While the invention has been particularly shown and described with reference to the preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention.

Claims (43)

1. A conveying belt device comprising a loop structure of a conductive loaded, resin-based material comprising conductive materials in a base resin host wherein said belt or fragments of said belt are detectable by a metal detection device.

2.The device according to Claim 1 wherein the ratio, by weight, of said conductive materials to said resin host is between about 0.20 and about 0.40.

3.The device according to Claim 1 wherein said conductive materials comprise metal powder.

4.The device according to Claim 3 wherein said metal powder is nickel, copper, or silver.

5.The device according to Claim 3 wherein said metal powder is a non-conductive material with a metal plating.

6.The device according to Claim 5 wherein said metal plating is nickel, copper, silver, or alloys thereof.

7.The device according to Claim 3 wherein said metal powder comprises a diameter of between about 3 µm and about 12 µm.

8.The device according to Claim 1 wherein said conductive materials comprise a combination of metal powder and non-metal powder.

9.The device according to Claim 1 wherein said conductive materials comprise micron conductive fiber.

10.The device according to Claim 9 wherein said micron conductive fiber is nickel plated carbon fiber, stainless steel fiber, copper fiber, silver fiber or combinations thereof.

11.The device according to Claim 10 wherein said micron conductive fiber has a diameter of between about 3 µm and about 12 µm and a length of between about 2 mm and about 14 mm.

12.The device according to Claim 1 wherein said conductive materials comprise a combination of conductive powder and conductive fiber.

13.The device according to Claim 1 wherein said conductive loaded resin-based material is a fabric.

14.The device according to Claim 1 wherein said device comprises a plurality of connected segments of said conductive loaded resin-based material.

15.The device according to Claim 14 further comprising a metal hinge embedded in each said segment.

16.The device according to Claim 1 wherein said base resin comprises a flame-retardant material.

17.The device according to Claim 1 further comprising a metal layer overlying said conductive loaded resin-based material.

18. A food processing conveying apparatus comprising:
a belt of a conductive loaded, resin-based material comprising conductive materials in a base resin host; and a metal detector wherein said belt or fragments of said belt are detectable by said metal detector.

19.The apparatus according to Claim 18 wherein the ratio, by weight, of said conductive materials to said resin host is between about 0.20 and about 0.40.

20.The apparatus according to Claim 18 wherein said conductive materials comprise metal powder.

21. The apparatus according to Claim 20 wherein said metal powder is a non-conductive material with a metal plating.

22.The apparatus according to Claim 18 wherein said conductive materials comprise a combination of metal powder and non-metal powder.

23.The apparatus according to Claim 18 wherein said conductive materials comprise micron conductive fiber.

24.The apparatus according to Claim 18 wherein said conductive materials comprise a combination of conductive powder and conductive fiber.

25.The apparatus according to Claim 18 wherein said conductive loaded resin-based material is a fabric.

26.The apparatus according to Claim 18 wherein said belt comprises a plurality of segments of said conductive loaded resin-based material.

27.The apparatus according to Claim 26 further comprising a metal hinge embedded in each said segment.

28.The apparatus according to Claim 26 further comprising a drive sprocket coupled to said belt wherein said drive sprocket comprises said conductive loaded resin-based material.

29.The apparatus according to Claim 18 wherein said belt comrpises a continuous piece of said conductive loaded resin-based material formed by binding together to opposite ends of said conductive loaded resin-based material.

30.The apparatus according to Claim 29 wherein said binding is by ultrasonic welding.

31. The apparatus according to Claim 18 wherein said base resin comprises a flame-retardant material.

32.The apparatus according to Claim 18 further comprising a metal layer overlying said conductive loaded resin-based material.

33.The apparatus according to Claim 18 further comprising a chute or guide formed of said conductive loaded resin-based material.

34.A method to form a conveying belt device, said method comprising:
providing a conductive loaded, resin-based material comprising conductive materials in a resin-based host; and molding said conductive loaded, resin-based material into a conveying belt device comprising a loop structure of a conductive loaded, resin-based material comprising conductive materials in a base resin host wherein said conveying belt or fragments of said conveying belt are detectable by a metal detection device.

35.The method according to Claim 34 wherein the ratio, by weight, of said conductive materials to said resin host is between about 0.20 and about 0.40.

36.The method according to Claim 34 wherein the conductive materials comprise a conductive powder.

37.The method according to Claim 34 wherein said conductive materials comprise a micron conductive fiber.

38.The method according to Claim 34 wherein said conductive materials comprise a combination of conductive powder and conductive fiber.

39.The method according to Claim 34 wherein said molding comprises:
injecting said conductive loaded, resin-based material into a mold;
curing said conductive loaded, resin-based material;
and removing said conveying belt device from said mold.

40. The method according to Claim 39 wherein said conveying belt device comprises a plurality of segments coupled together and wherein said step of molding comprises molding said segments.

41. The method according to Claim 40 further comprising placing a metal hinge in said mold prior to said step of injecting said conductive loaded, resin-based material into a mold.

42.The method according to Claim 34 wherein said molding comprises:
loading said conductive loaded, resin-based material into a chamber;
extruding said conductive loaded, resin-based material out of said chamber through a shaping outlet; and curing said conductive loaded, resin-based material to form said conveying belt device.

43.The method according to Claim 42 further comprising bonding two ends of said molded conductive loaded resin-based material by ultrasonic welding.