Compound Switching Apparatus for Tire Tread Formation
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Solution Overview
Problem
Tire manufacturers face challenges in efficiently mixing multiple rubber compounds for tire treads due to high costs and inefficiencies associated with banbury mixers, which struggle with tough compounds and result in compound wastage if not used promptly.
Innovation Solution
An apparatus and method utilizing two extruders and gear pumps to independently flow and mix two or more rubber compounds directly on a tire building machine, allowing for a single or reduced number of stations and reduced cycle time, enabling custom tire tread formation with a multicap tread design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple banbury mixers are used to process different rubber compounds, then the ability to produce various tire compounds is improved, but the capital expenditure and manufacturing cost increase significantly
Solution Approach 1:
The patent combines multiple compound delivery systems into a single extruder unit with multiple hoppers, allowing different rubber compounds to be fed and processed through one integrated system rather than requiring separate banbury mixers for each compound type
Solution Approach 2:
The extruder system is designed to handle multiple rubber compounds simultaneously through a single device, making the extruder a universal processing unit that can produce various tire compounds without requiring dedicated mixers for each compound type
2Quantity of substance
If banbury mixers are used to mix rubber compounds, then compound production is achieved, but the mixing of tough or stiff rubber compounds becomes difficult
Solution Approach 1:
The patent replaces the traditional banbury mixer mechanical system with an extruder-based system that uses screw conveyance and shear mixing mechanisms, which are more effective at handling tough and stiff rubber compounds while maintaining production capability
3Ease of manufacture
If compounds are shipped from banbury mixers to tire building plants, then compound production is separated from tire manufacturing, but transportation costs and cycle time increase
Solution Approach 1:
The patent merges the compound preparation and tire building operations by integrating the extruder system directly with the tire building machine, eliminating the need to ship compounds separately and reducing handling time while maintaining process separation benefits
4Adaptability or versatility
If multiple compounds are kept in inventory for different tire lines, then production flexibility is improved, but storage costs and compound wastage increase
Solution Approach 1:
The patent enables continuous production of different rubber compounds on-demand through the extruder system, eliminating the need to maintain large inventories of pre-mixed compounds and reducing wastage from expired materials while maintaining production flexibility
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 reduces the need for multiple compounds and stations, lowers costs, and allows for efficient, on-site tire tread production, minimizing waste and enhancing production efficiency by enabling continuous application of mixed compounds directly on the tire building drum.
Implementation Method 1
A gear pump is positioned in each channel
Implementation Method 2
a first extruder for processing a first compound; and a second extruder for processing a second compound
Data Source
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AI summary
An apparatus for applying a mixture of two compounds and a method for forming a tire tread on a green tire carcass are disclosed. The apparatus comprises a first extruder (30) in fluid communication with a first gear pump (42) for processing a first compound; and a second extruder (60) in fluid communication with a first gear pump (44) for processing a second compound. The outlet of each gear pumps (42,44) are each in fluid communication with a channel of a nozzle (80). The two gear pumps are positionned in a single housing. The method comprises the steps of: providing a tire building drum having a green tire carcass thereon; applying a strip of a first base compound over a portion of the green tire carcass forming a first layer (100); applying a first tread cap layer (104) over the first layer; applying a strip of a second base compound over a second portion of the green tire carcass forming a second layer (108) of base compound forming a chimney (110); and applying a second tread cap layer (112) over the second layer.