Water based urethane as predip for carbon fiber cord

1. A method of manufacturing a belt comprising:

laying up a first elastomeric layer of a belt build on a mandrel;

laying up a tensile reinforcement layer on the first elastomeric layer, wherein the tensile reinforcement layer comprises cords coated with a water based urethane compound;

laying up a second elastomeric layer on the first elastomeric layer and the tensile reinforcement layer;

curing the belt build in a profile-forming mold; and

cutting the belt build to predetermined belt widths and/or lengths;

wherein the water based urethane compound is a dispersion of polyurethane polymer;

wherein the cords are twisted together at a rate of from 0.75 to 2.5 turns per inch before being coated with the water based urethane compound; and,

wherein the cords are further coated with a resorcinol-formaldehyde-latex suspension, and a final dip through a rubber based polymer to provide an overcoat.

2. The method of claim 1 further comprising laying up a fabric layer material on the second elastomeric layer.

3. The method of claim 1 wherein the second elastomeric layer is a cushion layer disposed on the tensile reinforcement layer.

4. The method of claim 3 further comprising laying up an insulating layer material on the cushion layer.

5. The method of claim 4 further comprising laying up a fabric layer on the insulating layer material.

6. The method of claim 1 wherein the second elastomeric layer comprises a plurality of longitudinal ribs and a plurality of longitudinal grooves formed therein after curing the belt build.

7. The method of claim 1 wherein the second elastomeric layer comprises a plurality of troughs and a plurality of projections orientated perpendicular to the longitudinal direction of the belt, the troughs and the projections formed therein after curing the belt build.

8. The method of claim 1 wherein the tensile reinforcement layer comprises carbon fiber cords.

9. The method of claim 1 wherein the cords are coated by dipping in a tank comprising a polyurethane emulsion stabilized with internal anionic and external nonionic species.

10. The method of claim 9 wherein the polyurethane emulsion is substantially free of polyurea functional groups.

11. The method of claim 9 wherein the polyurethane emulsion is substantially free of isocyanate functional groups.

12. The method of claim 9 where pickup percentage is from about 5% to about 40% by weight, as compared from before dipping the cord to after dipping the cord in the dipping process.

13. A method comprising:

providing a plurality of cords;

twisting the plurality of cords together at a rate of from 0.75 to 2.5 turns per inch;

after the twisting the plurality of cords together, then dipping the plurality of cords in a first tank comprising a polyurethane emulsion stabilized with internal anionic and external nonionic species, dipping the plurality of cords a second tank comprising a resorcinol-formaldehyde-latex suspension, and dipping the plurality of cords a third tank comprising rubber based polymer, to provide a plurality of treated cords;

providing a first elastomeric layer;

laying up the plurality of treated cords on the first elastomeric layer to form a tensile reinforcement layer;

laying up a second elastomeric layer on the tensile reinforcement layer; and,

curing the combination of the first elastomeric layer, the tensile reinforcement layer and the second elastomeric layer in a profile-forming mold.

14. The method of claim 13 further comprising cutting the cured combination of the first elastomeric layer, the tensile reinforcement layer and the second elastomeric layer to provide a belt with a predetermined width and/or length.

15. The method of claim 13 wherein the plurality of cords are carbon fiber cords.

16. The method of claim 13 wherein the plurality of cords are helically wound in forming the tensile reinforcement layer.

17. The method of claim 13 wherein pickup percentage is from about 5% to about 40% by weight, as compared from before dipping the plurality of cords to after dipping the plurality of cords in the first, second and third tanks.

18. The method of claim 13 wherein the polyurethane emulsion is substantially free of isocyanate functional groups.