Composite Web Tire Ply Sections for Cost and Reliability
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Solution Overview
Problem
The production of pneumatic radial tires is hindered by high material and production costs due to the need for specialized embedding mixtures with enhanced crack resistance, fatigue resistance, and penetration resistance, particularly in the end sections and edge sections of the belt and carcass plies, which are currently addressed with expensive formulations and additional barrier layers.
Innovation Solution
A method involving the creation of composite webs with alternating sections of different rubber mixtures, allowing for the use of high-performance mixtures only in critical areas while using standard mixtures elsewhere, optimized through a calendering process that integrates reinforcement webs between these mixture sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive specialized embedding mixtures are used throughout the entire belt and carcass plies, then crack resistance, fatigue resistance, and penetration resistance are improved, but material costs and production costs increase significantly
Solution Approach 1:
The patent applies local quality by differentiating the embedding mixture composition across different spatial locations within the tire structure. Specifically, the end sections of carcass plies and edge sections of belt plies use a first embedding mixture with enhanced crack and fatigue resistance, while the central sections use a second, more cost-effective embedding mixture. This localized differentiation ensures that expensive materials are applied only where structurally critical, thereby improving reliability in high-stress zones without proportionally increasing overall material costs.
2Reliability
If a separate barrier rubber layer is introduced between the carcass and inner layer to prevent cord penetration, then penetration resistance is improved, but tire weight increases and manufacturing becomes more expensive
Solution Approach 1:
The patent eliminates the need for a separate barrier rubber layer by incorporating penetration resistance directly into the embedding mixture formulation used in the carcass ply end sections. The first embedding mixture is specifically designed with properties that prevent cord penetration while maintaining flexibility. This integrated approach provides the necessary penetration resistance in the critical basket arch areas without adding the extra weight and complexity of a separate barrier layer.
Solution Approach 2:
The patent merges the functions of multiple requirements into a single embedding mixture formulation. The first embedding mixture simultaneously provides crack resistance, fatigue resistance, and penetration resistance in the carcass ply end sections. This consolidation eliminates the need for separate functional layers, thereby reducing overall tire weight and simplifying the manufacturing process while maintaining comprehensive protective properties.
3Ease of manufacture
If uniform embedding mixtures are used for all sections of belt and carcass plies, then manufacturing simplicity is maintained, but sections subject to special loads lack optimized performance
Solution Approach 1:
The patent implements local quality by defining specific geometric boundaries for different mixture applications. The end sections of carcass plies and edge sections of belt plies are identified as requiring the first embedding mixture, while central sections use the second mixture. This spatial differentiation ensures that sections subject to special loads receive optimized performance characteristics while maintaining a relatively simple manufacturing process through clear demarcation of application zones.
4Reliability
If the width of special mixture sections is increased to cover more critical areas, then reliability under special loads is improved, but material costs and manufacturing complexity increase
Solution Approach 1:
The patent optimizes the width of special mixture sections to precisely match the critical load-bearing zones. The first embedding mixture is applied to the end sections of carcass plies and edge sections of belt plies - specifically defined areas where stress concentration occurs during tire operation. This precise localization ensures adequate reliability without unnecessarily expanding the application area, thereby controlling both material costs and manufacturing complexity.
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 material and production costs while maintaining tire durability by tailoring specific sections of the tire plies with optimized embedding mixtures, specifically enhancing resistance properties where needed without increasing tire weight.
Implementation Method 1
two composite webs with a reinforcement web to be positioned between them being joined by calendering
Implementation Method 2
the reinforcements for passenger car tires usually being a component of a textile fabric and steel cords usually being used as reinforcements in radial carcasses for truck tires. The compositions of the embedding mixtures are different for the belt plies and the carcass plies
Data Source
Figure 1
Figure 2
Figure 3~3a
AI summary
The method involves providing multiple mixture strips on a mixture track. One mixture strip is made of a rubber compound, where another mixture strip is made of another rubber compound. The mixture track is sectioned transversely or at an acute angle of the longitudinal extension of the track sections. An independent claim is also included for a vehicle radial tire.