Ceramic Coated Wear Plates in Vulcanizing Device
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Solution Overview
Problem
The existing vulcanizing devices for vehicle tires suffer from significant wear of metal surfaces due to microwelding during opening and closing, leading to positional changes and defects like step-off, conicity, and side thrust variations in the vulcanized tires, resulting in increased operational costs and production issues.
Innovation Solution
The implementation of ceramic-coated wear plates on the closure ring and lower plate surfaces within the vulcanizing device, which prevent direct metal-to-metal contact, reducing microwelding and wear by using a non-metallic ceramic coating that withstands heat, mechanical stress, and friction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal surfaces move against each other during vulcanizing device operation, then the device can perform its function of forming tyres, but significant wearing occurs due to micrawelding between metal surfaces
Solution Approach 1:
The patent applies composite materials by coating metal surfaces with ceramic material to create a composite surface structure. The ceramic coating layer (alumina,氧化铝) is applied on wear plates that contact moving metal surfaces, combining the structural strength of metal with the wear resistance of ceramic. This resolves the contradiction by maintaining the mechanical functionality of metal while protecting against micrawelding-induced wear through the ceramic barrier layer.
2Force
If metal surfaces are in slide contact under high surface pressure, then the vulcanizing device can apply necessary force to form the tyre, but micrawelding causes wearing and positional changes
Solution Approach 1:
The patent introduces an intermediary ceramic coating layer between the metal surfaces that are in slide contact. This ceramic layer acts as a mediator that prevents direct metal-to-metal contact and micrawelding while still allowing the transmission of necessary surface pressure for tyre formation. The wear plate with ceramic coating receives the axial force from the closure ring and transmits it radially to the segment shoes without experiencing micrawelding wear.
3Productivity
If the vulcanizing device operates continuously, then production efficiency is maintained, but wearing of metal surfaces requires periodic part replacement causing breaks
Solution Approach 1:
The patent changes the material parameter of the wear plate surfaces by applying ceramic coating, which fundamentally alters the wear characteristics. This material parameter change enables continuous operation without periodic part replacement, as the ceramic-coated surfaces resist micrawelding wear that would otherwise require maintenance interruptions. The ceramic layer's superior wear resistance allows the device to maintain continuous productivity.
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 solution significantly reduces surface wear, maintains the precise positioning of device parts, enhances tire quality by minimizing conicity and side thrust variations, and extends the operational life of the vulcanizing device components.
Implementation Method 1
the friction between a ceramical coating layer and a segment shoe is small
Implementation Method 2
wearing of the surfaces is low, wherein the position of the parts of the vulcanising device remains more likely as desired
Data Source
Figure 1
Figure 2~3
AI summary
A vulcanising device (1 ) of a vehicle tyre comprising a lower plate (13), on which segments shoes (6) are fitted, on which segment shoes (6) profile segments (5) are arrangeable in order to form a tread pattern in the tyre blank to be vulcanised, and a closure ring (7) for moving the segment shoes (6) in the radial direction (X) of the closure ring (7), which is placed around the segment shoes (6) against the back surfaces (15) of the segment shoes (6). The closure ring (7) comprises wear plates (8), which are coated with a ceramic coating layer (9), which wear plates (8) are arranged on the inner surface of the closure ring (7) so that the ceramic coating layers (9) are fitted against the back surfaces (15) of the segment shoes (6), and/or the lower plate (13) comprises wear plates (8), which are coated with a ceramic coating layer (9), which wear plates (8) are arranged on the surface of the lower plate (13) so that the ceramic coating layers (9) are fitted against the lower surfaces of the segment shoes (6).