Continuous Tyre Sealing Compound Production via Buffer Decoupling
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Solution Overview
Problem
Current methods for producing self-sealing tyre semi-finished products with a continuous strip of sealing compound are not suitable for industrial mass production due to complexity, long execution times, and lack of precise control over longitudinal uniformity, making them unsuitable for high-volume, low-cost production with high automation.
Innovation Solution
A continuous production process involving a continuous mixer, buffer device, and gear pump, linked in series with structural continuity, to decouple mixing and shaping operations, ensuring precise control over the sealing compound's uniformity and stability, resulting in a semi-finished product with excellent longitudinal uniformity and reduced risk of scorching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional discontinuous production methods are used, then flexibility in processing is maintained, but production volume is low and processing time is long
Solution Approach 1:
The patent implements a continuous production process where the extruder, buffer device, and gear pump operate continuously without interruption. The sealing compound is fed continuously from the extruder through the buffer device to the gear pump, eliminating the need for batch processing and loading/unloading operations, thereby significantly increasing production volume and reducing processing time.
Solution Approach 2:
The production process is segmented into distinct functional zones: mixing zone in the extruder, buffering zone in the buffer device, and metering/shaping zone in the gear pump. This segmentation allows each component to be optimized for its specific function while operating in continuous sequence, resolving the contradiction between productivity and processing time.
2Productivity
If mixing and shaping are combined in one continuous operation, then productivity increases, but control over longitudinal uniformity deteriorates
Solution Approach 1:
The buffer device acts as an intermediary element between the extruder and gear pump. It receives the sealing compound from the extruder, allows internal pressure equalization and homogenization, then feeds it to the gear pump. This intermediary function decouples the mixing and shaping operations, maintaining longitudinal uniformity while enabling continuous production.
Solution Approach 2:
The buffer device performs preliminary actions of pressure equalization and material homogenization before the sealing compound enters the gear pump for precise metering and shaping. This preliminary processing ensures that the material is properly prepared for the shaping operation, maintaining manufacturing precision in the continuous process.
3Productivity
If high-speed continuous processing is used, then productivity increases, but risk of scorching increases
Solution Approach 1:
The buffer device provides a cushioning effect by allowing pressure equalization and temporary storage of the sealing compound. This cushioning prevents pressure surges and excessive heat generation that could cause scorching, while still enabling high-speed continuous processing through the subsequent gear pump metering system.
4Extent of automation
If traditional production methods are used, then equipment complexity is low, but automation level is low and costs are high
Solution Approach 1:
The patent merges the functions of mixing, buffering, metering, and shaping into a single integrated continuous production line. The extruder, buffer device, and gear pump are connected in series to form a unified automated system, increasing automation level while the functional integration actually simplifies the overall process control compared to multiple discrete operations.
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 process enables the production of semi-finished products with high longitudinal uniformity and reduced processing time, suitable for industrial-scale production of self-sealing tyres with improved size stability and manageable internal tensions, optimizing both mixing and shaping operations.
Implementation Method 1
mixing the components while they advance in the continuous mixer until the sealing compound is obtained
Implementation Method 2
a buffer device, both provided with a respective inner chamber. The buffer device is arranged and structured for receiving the sealing compound from the continuous mixer and for feeding the gear pump
Implementation Method 3
a gear pump, both provided with a respective inner chamber... continuously feeding, by means of the gear pump, the sealing compound to an extrusion head
Implementation Method 4
an extrusion head coupled directly and with structural continuity to the gear pump... to deliver in output the sealing compound in the form of a strip with predetermined transverse size
Data Source
Figure 1
Figure 2
Figure 3a
AI summary
An apparatus (100), and relative method, for producing a semi-finished product (50) comprising a strip of sealing compound (51) for building tyres (1), comprising at least one unsaturated styrene thermoplastic elastomer, one bonding resin and one cross-linking agent; wherein the apparatus comprises a continuous mixer (101 ) comprising an inner chamber (103) for receiving the components of the sealing compound and to continuously mix them until the sealing compound is obtained; a buffer device (110) having a respective inner chamber (111) and coupled in series with structural continuity to the continuous mixer, downstream of the latter; a gear pump (120) having a respective inner chamber (121) and a gear system (122) housed in the respective inner chamber, and coupled with structural continuity to the buffer device downstream of the latter, an extrusion head (130) coupled directly and with structural continuity to the gear pump, downstream of the latter, in a manner such to receive in input the sealing compound from the gear pump and deliver in output the sealing compound in the form of a strip having predetermined transverse size, wherein the buffer device (110) receives the sealing compound from the continuous mixer (101) and feeds the gear pump.