Continuous Tire Tread Extrusion Molding Curing System
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Solution Overview
Problem
Conventional tire tread manufacturing is inefficient due to a non-continuous process that results in heat energy loss, labor-intensive handling, and the need for multiple reheating steps, leading to increased energy and labor costs.
Innovation Solution
A system for continuous extrusion, molding, and curing of tire tread using a series of adjacent mold sectors within a heated press, where rubber material is extruded and molded in a continuous process, minimizing heat loss and eliminating intermediate storage, with the ability to adjust for different rubber materials and precise control over curing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional non-continuous extrusion and molding process is used, then flexibility in handling rubber material is maintained, but heat energy is lost during cooling and storage
Solution Approach 1:
The patent implements a continuous extrusion-molding-curing process where rubber material flows continuously from the extruder through the mold sectors without interruption. The synchronized movement of mold sectors and continuous rubber supply eliminate the cooling and storage steps inherent in conventional batch processing, thereby preventing heat energy loss while maintaining high productivity.
Solution Approach 2:
The patent combines multiple discrete operations (extrusion, molding, and curing) into a single integrated continuous process. By merging these previously separate steps into one streamlined operation, the system eliminates the intermediate cooling and reheating cycles that cause energy loss, while the combined process maintains operational flexibility.
2Ease of manufacture
If manual handling and storage of rubber strips is used, then flexibility in production scheduling is maintained, but labor costs and storage space requirements increase
Solution Approach 1:
The continuous process eliminates the need for manual handling, storage, and intermediate processing of rubber strips. The rubber material flows continuously through the system from extrusion to molding, removing the labor-intensive operations and storage requirements while significantly improving production efficiency and throughput.
Solution Approach 2:
The system is designed to automatically feed rubber material from the extruder directly into the mold sectors without requiring manual intervention. The continuous automated process eliminates the need for workers to handle, position, and store rubber strips, thereby reducing labor costs and space requirements while maintaining high productivity.
3Use of energy by moving object
If multiple reheating steps are applied to rubber strips, then complete curing is achieved, but temperature control complexity and energy consumption increase
Solution Approach 1:
The continuous process allows rubber material to be heated and cured in a single uninterrupted pass through the mold sectors. The continuous flow through the heated mold eliminates the need for multiple discrete reheating steps, reducing both energy consumption and the complexity of temperature control while ensuring complete curing.
Solution Approach 2:
The patent combines heating, molding, and curing operations into a single integrated process step. By merging these functions into one continuous operation within the heated mold sectors, the system achieves complete curing in a single heating cycle, thereby reducing energy consumption and simplifying temperature control compared to multiple separate reheating steps.
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 energy consumption, eliminates storage and reheating costs, and allows for more accurate control of the molding process, enhancing overall efficiency and productivity.
Implementation Method 1
The press is used to apply heat and pressure to the elongated strip by pressing the mold sectors between multiple platens
Implementation Method 2
the rubber is heated and fluidized. Pressure from the extruder screw forces the rubber through a die
Data Source
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AI summary
A system for the continuous extrusion, molding, and curing of tread rubber is provided. A plurality of discrete mold sectors are arranged adjacent to each other along a longitudinal axis between an in-feed and an out-feed of a mold sector transport mechanism that extends through a heated press. As the mold sectors are continuously advanced along a process direction in steps, rubber material is extruded and placed onto at least one of the mold sectors near the in-feed end such that an elongated strip of rubber material extends over multiple mold sectors along the longitudinal axis. As the strip of rubber material exits the press, the mold sectors are sequentially removed from the rubber material and returned to the in-feed. An extruder outlet positioned near the in-feed can be moved towards or away from the mold sectors to supply rubber material and prevent backflow.