Composite Tire Tread With Targeted Stiffness Gradient Control
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Solution Overview
Problem
Tire manufacturers face challenges in efficiently mixing multiple rubber compounds for tire treads due to the high costs associated with banbury mixers, difficulties in mixing stiff compounds, and the limited shelf life of compounds, leading to increased costs and inefficiencies.
Innovation Solution
A method and apparatus for forming a composite tire tread with a targeted stiffness gradient using a coextruded strip of two different rubber compounds, which allows for independent flow of compounds from a single application head, enabling efficient custom tread formation directly on a tire building machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple rubber compounds are mixed using banbury mixers, then the tire tread can meet customer demands for different performance characteristics, but the manufacturing cost increases due to expensive capital expenditures and transportation costs
Solution Approach 1:
The patent combines multiple rubber compound delivery systems into a single application head that can independently dispense different compounds. This merging eliminates the need for multiple separate mixing stations and reduces transportation requirements, thereby lowering manufacturing costs while maintaining the ability to apply multiple compounds to meet different customer demands.
Solution Approach 2:
The application head is designed as a universal device that can handle and dispense multiple different rubber compounds through a single system. This multi-functional approach replaces the need for dedicated banbury mixers for each compound, reducing capital expenditures and simplifying the manufacturing process while maintaining versatility in meeting customer requirements.
2Adaptability or versatility
If multiple rubber compounds are prepared in advance, then the tire building process can use different compounds for different tread regions, but the compound shelf life is limited and unused compound is scrapped
Solution Approach 1:
The system enables on-demand compound dispensing where the application head draws compounds directly from storage and applies them immediately to the tire tread as needed. This self-service approach eliminates the need to pre-mix large quantities of compound, allowing the system to use only the specific amounts required for each tire, thereby minimizing waste from expired or unused compound.
Solution Approach 2:
The patent implements preliminary storage of rubber compounds in a controlled environment at the tire building location, followed by on-demand dispensing. This preliminary preparation in small quantities, rather than large-scale pre-mixing, allows the system to maintain compound freshness and reduce waste while still providing the versatility of multiple compound types.
3Productivity
If a single application head delivers multiple compounds, then the production efficiency increases by reducing multiple stations, but the control of compound flow and stiffness gradient precision becomes more challenging
Solution Approach 1:
The application head is segmented into multiple independent delivery channels or zones, each capable of controlling the flow of specific rubber compounds independently. This segmentation allows precise control over the composition and stiffness gradient of the applied tread material while maintaining a compact single-head design, thus preserving both productivity and manufacturing precision.
Solution Approach 2:
The system applies different rubber compounds with specific properties to different local regions of the tire tread based on required performance characteristics. By controlling the spatial distribution and flow rates of each compound independently within the single application head, the system achieves precise stiffness gradients and compound placement while maintaining high production efficiency.
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 reduces the need for multiple stations, minimizes compound waste, and allows for precise control of stiffness gradients across the tread, enhancing tire performance while reducing production costs.
Implementation Method 1
an apparatus for forming a green (uncured) tire tread by coextruding a first and second layer of a dual layer strip of two different compounds
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 second 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.