Coextruded Tire Strip Application for Multi-Compound Tread Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Tire manufacturers face challenges in efficiently mixing multiple rubber compounds due to high costs and inefficiencies in banbury mixers, leading to compound waste and limited shelf life, which complicates tire production and increases operational costs.
Innovation Solution
A dual compound switching apparatus with coextrusion nozzle that allows independent flow and application of two or more rubber compounds directly onto a tire building machine, enabling efficient and customizable tire tread production without the need for multiple stations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple rubber compounds are mixed using banbury mixers, then tire components can meet customer demands with multiple compounds, but the number of compounds needed increases leading to high costs and extensive capital expenditures
Solution Approach 1:
The patent combines multiple rubber compound delivery systems into a single coextrusion head that can independently deliver multiple compounds simultaneously. This merging eliminates the need for multiple separate banbury mixers and compound storage systems, reducing device complexity while maintaining the ability to use multiple rubber compounds in tire components.
Solution Approach 2:
The coextrusion head is designed as a universal device that can handle multiple different rubber compounds through independent channels. This multi-functional apparatus can switch between and combine various compounds as needed, replacing the need for dedicated mixers for each compound type and reducing the overall number of compounds that must be maintained in inventory.
2Ease of manufacture
If multiple banbury mixers are used for different rubber compounds, then each compound can be prepared separately, but transportation costs increase and shelf life becomes an issue requiring scrapping of unused compounds
Solution Approach 1:
The system prepares rubber compounds in advance and stores them in the coextrusion head's channels, ready for immediate use. This preliminary preparation eliminates the need for separate transportation of compounds from multiple banbury mixers to the tire building plant, and compounds are used immediately upon extrusion, preventing waste from limited shelf life.
Solution Approach 2:
The invention extracts the compound preparation and delivery function directly to the tire building machine through the coextrusion head. This eliminates the intermediate transportation step and the associated waste from compounds that cannot be used within their shelf life, as compounds are prepared and applied on-demand at the point of use.
3Duration of action of moving object
If banbury mixers are used to mix rubber compounds, then compounds can be prepared in advance, but the mixers have difficulty mixing tough or stiff rubber compounds effectively
Solution Approach 1:
The patent replaces the mechanical mixing system of banbury mixers with a direct extrusion system. Instead of relying on mechanical mixing that struggles with tough compounds, the system extrudes pre-prepared compounds through a coextrusion head, eliminating the mixing reliability issue while maintaining advance preparation capabilities.
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
Enables efficient and cost-effective production of custom tire treads by allowing independent flow and application of multiple rubber compounds, reducing the need for additional equipment and minimizing waste, while maintaining compound freshness and flexibility in composition.
Implementation Method 1
The coextrusion nozzle has a first flow passageway in fluid communication with a first compound source and a second flow passageway in fluid communication with a second compound source. The coextrusion nozzle has a low volume coextrusion zone where the first compound flow stream joins with the second compound flow stream.
Data Source
AI summary
One or more embodiments of the present invention provide an apparatus for applying a mixture of a first compound and a second compound, the apparatus comprising a first extruder for processing a first compound and a second extruder for processing a second compound, wherein the outlet from the first extruder is in fluid communication with a first channel of a housing, and the outlet from the second extruder is in fluid communication with a second channel of the housing, wherein a gear pump is positioned in each channel, wherein a nozzle is in fluid communication with an outlet of the first channel and an outlet of the second channel, and a coextruded continuous strip is produced. The ratio of the first compound to the second compound may be adjusted instantaneously.