Continuous Tire Ply Manufacturing with Adjustable Cord Spacing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The existing methods for manufacturing tire components, particularly ply, result in tire nonuniformity due to multiple splices, variations in cord spacing, and difficulty in changing tire types or sizes on a given drum, with increased strength and reduced flexibility at splice locations, and challenges in producing ply with angular variations.

Innovation Solution

An apparatus that allows for the instantaneous adjustment of cord spacing, angle, and width without equipment shutdown, using an adjustable epi die and calender system to create uniform tire ply components with no detectable splices, enabling easy switching between different tire configurations on a tire building drum.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Length of moving object

If multiple splices are used to join ply segments, then the circumferential length can be achieved, but tire nonuniformity increases due to mass distribution variations and cord overlap

Engineering Contradiction:

Improvecircumferential lengthVSAvoidtire uniformity

Core Design Contradiction:

Length of moving objectVSManufacturing precision

Solution Approach 1:

The patent implements a continuous ply making process where cords are continuously fed through a calendering system to form an unbroken ply layer around the tire building drum, eliminating the need for discrete segments and splices. This continuous action ensures uniform mass distribution and cord spacing throughout the entire circumferential length.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The invention extracts and removes the splicing operation from the ply manufacturing process entirely. By using a continuous calendering method, the harmful splicing step that causes cord overlap and mass nonuniformity is eliminated, leaving only the essential functions of cord placement and calendering.

Inventive Principle:

Principle #2Taking out (Extraction)

2Length of moving object

If splices are used to join ply segments, then the necessary circumferential length is achieved, but flexibility decreases and strength increases at splice locations

Engineering Contradiction:

Improvecircumferential lengthVSAvoidflexibility

Core Design Contradiction:

Length of moving objectVSDuration of action of moving object

Solution Approach 1:

The continuous calendering process produces a uniformly flexible ply layer without stiff splice joints. The uninterrupted calendering action ensures consistent rubber coating and cord embedding throughout, maintaining uniform flexibility around the entire tire circumference.

Inventive Principle:

Principle #20Continuity of useful action

3Productivity

If traditional ply making equipment is used, then production capacity is maintained, but adaptability to change tire types or sizes decreases due to equipment reconfiguration requirements

Engineering Contradiction:

Improveproduction capacityVSAvoidtire type switching

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system incorporates adjustable components including variable speed drives for cord feed reels, adjustable calender roll gaps and speeds, and programmable controllers that can be dynamically reconfigured for different tire specifications without physical reconfiguration, enabling quick adaptation while maintaining continuous production.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The calendering system is designed as a universal platform that can produce different tire ply types (radial, bias, diagonal) and sizes using the same basic equipment through software control and parameter adjustment, eliminating the need for dedicated equipment for each tire type.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If traditional calendering methods are used, then ply production is achieved, but manufacturing flexibility decreases when angular variation of cords is required

Engineering Contradiction:

Improveply productionVSAvoidcord angle variation

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The system uses variable speed drives on cord feed reels that can be independently controlled to achieve different cord angles by adjusting feed rates dynamically during operation, allowing easy transition between radial, bias, and diagonal ply configurations without equipment reconfiguration.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS7524398B2Apparatus for making tire components, and a tire

Publication Date: 2009.04.28 THE GOODYEAR TIRE & RUBBER CO

AI summary

An apparatus for making a reinforced elastomeric fabric having a gauge thickness G and a cord spacing S, the apparatus comprising: a die having a plurality of holes for receiving a reinforcement cord, the holes providing a cord spacing of about S/2, a first and second calender roll located adjacent the die, the die having a end plate having a slot wherein the slot is located adjacent a calender roll so that the reinforcement cords are pressed into engagement with a ribbon of elastomeric material, the calender rolls being spaced to provide a gauge thickness of about G/2, the apparatus further comprising a cutter for cutting the ribbon of reinforced elastomeric material into segments having a length L, each segment having a width W, each segment having lateral edges, said apparatus further comprising a pick arm for placing a plurality of segments onto a conveyor so that the lateral ends of adjacent segments are lap spliced together, the lap splice having a width W/2.