Calendered Tire Ply Conductive Insert Manufacturing
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Solution Overview
Problem
The integration of a conductive insert into a vehicle tire tread to manage static electricity is challenging due to the high silica content in the tread, which is a poor conductor of electricity, and existing methods complicate the production process by requiring post-calendering insertion or coextrusion.
Innovation Solution
A method and installation that calender a ply with a first rubber, then insert a second, conductive rubber into the bead before shaping, allowing for simultaneous formation of the insert within the tire blank, preserving dimensional qualities and simplifying the production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conductive insert is placed in the tread using coextrusion during extrusion, then electrical conductivity is improved, but the manufacturing process complexity increases
Solution Approach 1:
The conductive insert is placed in the tread during the extrusion process itself, before the tire components take their final shape. The insert is positioned in the extrusion channel along with the rubber mixture, allowing it to be automatically incorporated into the tread structure during forming, eliminating the need for separate insertion operations.
2Reliability
If the tread is formed by extrusion with insert coextrusion, then electrical connection is maintained, but the dimensional precision of the insert is compromised
Solution Approach 1:
The insert is pre-positioned in the extrusion channel before the extrusion process begins. This preliminary placement allows the insert to be accurately positioned relative to the tread geometry, and the subsequent extrusion process automatically maintains its position as the rubber mixture forms around it, achieving both precision and electrical connectivity.
3Adaptability or versatility
If post-calendering insertion is used to place the conductive insert, then manufacturing flexibility is improved, but the production time increases
Solution Approach 1:
The insertion of the conductive insert and the formation of the tread are merged into a single simultaneous operation. Both processes occur during the extrusion stage, eliminating the need for separate post-calendering insertion steps and reducing overall production time while maintaining manufacturing flexibility.
4Manufacturing precision
If the insert is inserted after calendering the ply, then the dimensional qualities of the ply are preserved, but the manufacturing process becomes more complex
Solution Approach 1:
The insert is positioned in the extrusion channel before the calendering process begins. This preliminary action allows the insert to be automatically incorporated into the tread during extrusion, and the subsequent calendering process uniformly compresses both the rubber and insert together, preserving dimensional qualities while simplifying the manufacturing process.
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
This approach ensures effective electrical conductivity while maintaining the tire's structural integrity, allowing for efficient discharge of electrical charges and simplifying the manufacturing process by inserting the conductive material before the tire takes its definitive shape.
Implementation Method 1
a calender forms, in a gap situated between two rollers, a ply comprising a first rubber, the calender forming a bead upstream of the gap
Implementation Method 2
the second rubber is fed by extrusion
Data Source
AI summary
A method for manufacturing a raw blank of a tyre includes using a calender to produce a ply. The calender includes two rollers with a gap situated therebetween. A ply that includes a first rubber material is formed in the gap of the calender, with a bead of the first rubber material being formed upstream of the gap. The bead and the gap of the calender are fed with a second rubber material, different from the first rubber material, to form at least one insert in the ply.