DESC:FIELD OF THE INVENTION
The present invention relates generally to material handling systems, particularly to a conveying system used to transfer materials across points located at same or different floors with capability to travel on routes consisting of horizontal, curved or inclined paths or their combinations thereof.

The instant invention more particularly relates to conveyors with flat top & zero gap for smooth and seamless conveying of items.

BACKGROUND OF THE INVENTION
Conveyor systems are generally known in the art. Conveyors are used in multiple industries to move and transport material from one place to another. And their type depends on the nature of its use.

It is well known in the prior art that the existing conveying systems, particularly the modular flat belts require a sliding structure across the length of the conveyor which is commonly made of multiple metal channels fixed with wear strips. Sliding of conventional belt require higher capacity motors to drive due to higher sliding friction. Applications needing longer conveying line require placing of multiple small conveyors serially due to the limited load carrying capabilities of conventional belts at higher loads & speeds. Each small conveyor will be needing additional motor drive set, sprockets, control components and integration.

In addition to the above-mentioned issue, the transfer points between small conveyors will have gaps. Though the gaps can be filled with transfer plates/rollers there are possibilities of small items or thin covers getting struck are higher. More number of structural components, sprockets, small belt modules increase the risks & failure possibilities in continuous operations also require more care, effort & time in production and installation.

So, as to overcome the above issues, it is essential to design and engineer a conveyor system with zero gaps.

OBJECTS OF THE INVENTION
An object of the invention to provide a conveyor system made of heavy duty flat top belt modules which are designed with zero gaps.

It is yet another object of the invention to disclose a conveying system with its 3-Dimensional capability, conveying routes with multiple complex incline/ decline/ any linear transitions implementable with single motor.

SUMMARY OF THE INVENTION
To meet the objects of the invention and overcome the drawbacks of the prior art it is disclosed here, a 3-Dimensional flat top conveyor system for continuous conveying of individual SKUs or verity of items mixed with complex dimension spectrum in warehousing & manufacturing industries.

The instant invention discloses a conveyor system made of heavy duty flat top belt modules which are designed with zero gaps. With its 3-Dimensional capability, conveying routes with multiple complex incline/ decline/ any linear transitions can be implemented with single motor.

BRIEF DESCRIPTION OF THE DRAWINGS
Fig.1 shows the images of existing conveying and distribution system.
Fig.2 shows the images of top and bottom views of the 3-Dimensional flat top belt module.
Fig.3 shows the images of the end bend & drive sprocket and belt section at inclination of the 3-Dimensional flat top belt module.
Fig.4 shows the image of the 3-Dimensional flat top multi track conveyor system wherein the scalability of the length is achieved by connecting multiple modules serially.
Fig.5 shows the images of the 3-Dimensional flat top conveyors and a flat top conveyor with divertors.

DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGs 1-3, a belt module (100) for use in a conveying system is disclosed. The belt module is generally made of hard and strong material. front side having a curved surface structure bending downwards with two slots (2) along the length of the front side of the module (100) to act as a knuckle for engaging with another module (100). The rear side having flat finishing with two extended engagement means (1) against the slots (2) for getting engaged by front side of another module in such a way that the flat rear side and curvy front side of the modules in serial connection makes zero gap between the modules. The bottom surface with the hinge structure of the slots and the extended engagement means in a position facing opposite direction in such a way that it engages a sprocket between the two engagement means (1) at the bottom for pulling the module. The bottom surface further comprises a plurality of ribs for providing adequate strength.

In the bottom side, there may be provision to provide one or more rollers (3) on either end of the module (100) to engage in channels and tracks. Moreover, the bottom side of the module is designed to get encaged with a drive system for pulling the module and drive the conveyor directly without needing any external drive chains.

FIG.3 shows the image of the conveyor system (200) with a plurality of the belt module coupled to one another by the encaging means, more particularly FIG.3 shows the end bend of the conveyor system connected to a drive sprocket (5) wherein the plurality of the belt modules adapted to be fitted with rollers to engage and move on a guiding track (4).

Referring to FIGs.4, a conveying system (200) with a plurality of the belt module coupled to one another by the encaging means and scalability in width is achieved by simply placing two or multiple belts together on customized shared track on common side of the belts. Wider belts with multiple tracks will also be driven with single motor to transfer materials across points located at same or different levels is disclosed. The conveying system (200) comprises of a plurality of belt modules (100) adapted to be fitted with rollers to engage and move on a guiding track (4). The belt module (100) has an upper surface and bottom surface. In the top side, a means to engage and be engaged by another module is provided. In the bottom side, there may be provision to provide one or more rollers (3) on either end of the module (100) to engage in channels and tracks. Moreover, the bottom side of the module is designed to get encaged with a customized sprocket for pulling the module and drive the conveyor directly without needing any external drive chains.

The system (200) of the present invention is used to transfer material across points located at same or different floors with capability to travel on routes consisting of Horizontal Curved and Inclined paths. The conveyor system (200) comprises of single molded, or 3D printed Modular Heavy-duty belt module (100) structure with assembled rollers (5) to carry loads on side guide rails without needing additional support structure underneath, wherein channels or profiles used as guiding tracks (4).

Referring to FIG.5, the present system is capable of delivering items at a raised height to trolleys or processing lines at mezzanine floors. The 3-Dimensional flat top conveyor therefore simplifies many complexities in implementation & operations also offers many unmatchable advantages than the conventional belts systems.

Advantages
• 3-Dimensional flat top conveyor with zero gap and driven with single motor despite multiple incline/ decline/ any linear transitions.
• System with rolling friction tactically reduces the effort requirement to handle even higher loads offers great savings in power and significant reduction in wear.
• Simplifies complex sorting applications require higher load capacity with greater speed/ throughput.
• Modular belt with simple bolted connection simplifies assembly and replacement of the belt modules.
• Conveyor with self-balanced & load carrying modular belts without needing external drive chains and sliding structure across the length also driven with single motor reduces total number of components to great extent.
• Overall simplified construction reduces the complexities in manufacturing, installation, operation, and maintenance and saves time, reduces failure possibilities.
• Various solution possibilities and advantages unmatchable with conventional conveyors.
,CLAIMS:We Claim:

1. A belt module (100) with flat upper surface comprising:
a front side having a curved surface structure bending downwards with two slots (2) along the length of the front side of the module (100) to act as a knuckle for engaging with another module (100);
a rear side having flat finishing with two extended engagement means (1) against the slots (2) for getting engaged by front side of another module (100) in such a way that the flat rear side and curvy front side of the modules in serial connection makes zero gap between the modules; and
a bottom surface with hinge structure of the slots and the extended engagement means in a position facing opposite direction in such a way that it engages a sprocket between the two engagement means (1) at the bottom for pulling the module;

2. The belt module (100) as claimed in claim 1, wherein the said belt module (100) may comprise of one or more rollers (3) to roll on a guiding track (4).

3. The belt module (100) as claimed in claim 1 wherein the bottom surface has plurality of ribs for providing adequate strength.

4. A conveying system (200) to transfer materials across points located at same or different levels, the conveying system (200) comprising of:
a plurality of belt modules (100) adapted to be fitted with rollers (3);
a guiding track (4) to engage and move the rollers (5); and
a drive system (5) to engage and push the belt module (100) on the track (4).

5. The conveying system (200) as claimed in Claim 4, wherein the width of the conveying system is scalable by simply placing two or multiple belts together on the guiding track (4) on common side of the belts.

6. The conveying system (200) as claimed in Claim 4, wherein the guiding track (4) may be channel or profiles.

7. The conveying system (200) as claimed in Claim 4, wherein the belt module (100) moves completely on the rollers (5) which reduces friction.