Composite Tire Tread Coextrusion With Variable Compound Ratio
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Solution Overview
Problem
Tire manufacturers face challenges in efficiently mixing multiple rubber compounds for tire components due to high costs, difficulty in mixing stiff compounds, and limited shelf life, which limits the ability to create custom tire treads with optimal characteristics like rolling resistance and durability.
Innovation Solution
A method and apparatus for forming a reinforced composite tread using a coextruded strip of two discrete rubber compounds, where the ratio of the compounds can be instantaneously varied, allowing for custom tread creation directly on a tire building machine, reducing the need for multiple stations and compounds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple rubber compounds are used in tire components to meet customer demands, then tire performance characteristics are improved, but manufacturing cost and complexity increase due to extensive capital expenditures for banbury mixers and transportation costs
Solution Approach 1:
The patent combines multiple rubber compound delivery systems into a single application head that can independently dispense two or more compounds. This merging eliminates the need for separate banbury mixers and multiple application stations, reducing capital expenditures and manufacturing complexity while maintaining the ability to produce treads with multiple rubber compounds for optimized performance characteristics.
Solution Approach 2:
The application head is designed with multi-functionality to dispense multiple rubber compounds through a single device. This universal application head can handle different compounds with varying viscosities and properties, replacing the need for specialized mixers for each compound type, thereby reducing overall device complexity while preserving performance benefits.
2Reliability
If multiple rubber compounds are used to create custom tire treads, then rolling resistance and wet traction are improved, but the number of compounds needed increases leading to higher transportation and storage costs
Solution Approach 1:
The invention segments the compound delivery system into independent flow channels within a single application head, allowing each compound to be delivered separately and precisely controlled. This segmentation enables the use of fewer total compounds while still achieving the desired tread performance characteristics through strategic placement and ratio control.
Solution Approach 2:
The application head enables local quality control by allowing different ratios of rubber compounds to be applied to different regions of the tread. This localized compound distribution optimizes performance characteristics like rolling resistance and wet traction in specific areas without requiring multiple complete sets of compounds, thereby reducing transportation and storage requirements.
3Stability of the object's composition
If banbury mixers are used to mix rubber compounds, then compound uniformity is achieved, but mixing of tough or stiff rubber compounds becomes difficult and costs increase
Solution Approach 1:
The rubber compounds are pre-mixed to a consistent state before being delivered to the application head. This preliminary mixing action ensures uniformity is achieved before application, eliminating the need for difficult on-site mixing of tough or stiff compounds. The pre-prepared compounds can then be independently dispensed without requiring additional mixing equipment or processes.
4Adaptability or versatility
If compounds are shipped to tire building plants, then production flexibility is maintained, but transportation costs and shelf life constraints increase
Solution Approach 1:
By merging multiple compound delivery capabilities into a single application head located at the tire building plant, the system eliminates the need for extensive compound transportation. This reduces transportation costs and minimizes the time compounds spend in transit, thereby preserving shelf life while maintaining production flexibility through on-demand compound application.
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 the creation of treads with improved rolling resistance, wet traction, and durability by targeting specific areas with high-stiffness compounds, reducing material waste and costs associated with multiple compounds and mixing equipment.
Implementation Method 1
A continuous coextruded strip is formed by an extruder
Data Source
AI summary
A method for forming a composite tread, the method comprising the steps of forming a coextruded strip of a first compound and a second compound, wherein the first compound is a tread compound, and the second compound is formed from a high-wear compound, wherein the tread is formed from winding the coextruded strip onto the tire building drum while varying the ratio of the first compound to the second compound.