Bidirectional Stitching Wheel for Green Tire Rubber Waste Reduction
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Solution Overview
Problem
Traditional tire manufacturing methods result in excessive waste of viscous rubber due to the rigid stitching wheel's inability to adapt to the varying dimensions of the green tire, leading to inefficient vulcanization and rubber distribution.
Innovation Solution
A bidirectional stitching wheel that is deformable in both rotational directions, featuring a fluid-filled or foamed polymeric structure with an interconnected web, allowing it to conform to the peaks and valleys of the green tire, thereby reducing rubber waste and improving vulcanization efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a rigid stitching wheel is used to stitch green rubber layers, then the stitching process is simple and stable, but excessive viscous rubber is wasted due to inability to adapt to varying tire dimensions
Solution Approach 1:
The stitching wheel is designed with a deformable structure that allows it to dynamically adjust its shape and conform to the varying dimensions of the green tire during the stitching process. This dynamic adaptability eliminates excessive rubber waste while maintaining stitching effectiveness.
Solution Approach 2:
The stitching wheel's physical parameters (shape, size, flexibility) are changed to match the varying dimensions of the green tire. This parameter adaptation enables the wheel to work efficiently with different tire sizes and shapes, reducing material waste.
2Manufacturing precision
If a rigid stitching wheel maintains constant distance pressure, then the stitching process is consistent, but rubber distribution during vulcanization is inefficient
Solution Approach 1:
The stitching wheel transitions from a rigid constant-pressure design to a dynamic deformable structure that adapts to the green tire's surface. This allows for consistent stitching while improving rubber distribution during subsequent vulcanization processes.
Solution Approach 2:
The stitching wheel incorporates flexible elements that can deform and conform to the tire surface, replacing the rigid structure. This flexibility enables better rubber flow and distribution during vulcanization while maintaining stitching precision.
3Device complexity
If a solid rigid wheel is used for stitching, then the device structure is simple, but the green tire volume between tire and mold features cannot be efficiently filled with rubber
Solution Approach 1:
The stitching wheel uses a flexible deformable structure instead of a solid rigid design. This flexibility allows the wheel to create optimal spacing and pathways for rubber flow, enabling efficient filling of the volume between the green tire and mold features during vulcanization.
Solution Approach 2:
The physical parameters of the stitching wheel (rigidity, shape, deformability) are changed to optimize rubber distribution. These parameter modifications improve the quantity and distribution of rubber in the mold cavity without significantly increasing device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The bidirectional stitching wheel reduces rubber waste by up to 20% and results in a lighter tire with improved appearance and reduced gauge variation, as it effectively aligns with the tire's geometry, minimizing rubber flow during vulcanization.
Implementation Method 1
The stitching wheel may be configured to be deformable to a substantially similar degree during rotation in both the first stitcher rotational direction and the second stitcher rotational direction
Implementation Method 2
The bidirectional stitching wheel may include a fluid filled stitching wheel
Implementation Method 3
A flexible intermediate layer may be disposed between the inner ring and the outer ring
Data Source
AI summary
A bidirectional stitching wheel may be able to conform to peaks and valleys of green rubber while building a tire. The bidirectional stitching wheel may include an inner ring including a stitcher rotation axis. The inner ring may be rotatable in a first stitcher rotational direction about the stitcher rotation axis. The inner ring may also be rotatable in a second stitcher rotational direction about the stitcher rotation axis. A flexible outer ring may be radially spaced from the inner ring. A flexible intermediate layer may be disposed between the inner ring and the outer ring. The flexible intermediate layer may be substantially equally deformable during rotation of the inner ring in both the first stitcher rotational direction and the second stitcher rotational direction.