Continuous Tyre Base Layer Joining With Aligned Stiffening Elements
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Solution Overview
Problem
Existing tyre manufacturing processes are inefficient and labor-intensive, particularly in the steps involving the formation and joining of tyre base layer end portions, leading to increased time and cost.
Innovation Solution
A method for joining first and second tyre base layer end portions by aligning stiffening elements and using welding or gluing techniques, along with the use of a sleeve or insert, to create a strong and continuous tyre base layer, which can be manufactured in a continuous process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual batch processes are used for tyre manufacturing, then flexibility in handling individual tyre components is maintained, but manufacturing efficiency and productivity are reduced
Solution Approach 1:
The tyre base layer is divided into multiple lengths, each with integrated stiffening elements. This segmentation allows continuous manufacturing while maintaining structural integrity, as each segment can be independently produced and then joined to form the complete circular base layer.
Solution Approach 2:
Stiffening elements are pre-integrated into the tyre base layer during manufacturing, rather than being added manually later. This preliminary action automates what would otherwise require manual placement and secures the stiffening elements in their correct positions before the joining process.
2Strength
If tyre base layer end portions are joined together, then a complete circular base layer is formed, but the join may create weak points that reduce structural strength
Solution Approach 1:
The stiffening elements are concentrated at the join region between end portions, providing localized reinforcement exactly where the join creates potential weakness. This local quality enhancement ensures the join area has equal or greater strength compared to the rest of the base layer.
Solution Approach 2:
The tyre base layer combines flexible base material with rigid stiffening elements (such as bead wires or polymer strips) to create a composite structure. This composite construction provides both the flexibility needed for tyre formation and the structural strength required to withstand operational stresses, particularly at the join point.
3Ease of manufacture
If multiple lengths of tyre base layer are joined, then the complete base layer can be manufactured in sections, but the manufacturing process complexity increases
Solution Approach 1:
The tyre base layer is manufactured in multiple discrete lengths that can be produced independently using continuous manufacturing processes. This segmentation simplifies production by allowing each length to be manufactured to standard specifications, then joined together to form the complete circular base layer.
Solution Approach 2:
All end portions are designed with matching interfaces and aligned stiffening elements, creating equivalent joining conditions throughout the manufacturing process. This equipotential design ensures that each join operation is identical in complexity and can be performed using the same standardized process, reducing overall manufacturing complexity.
4Stability of the object's composition
If stiffening elements are aligned during joining, then structural continuity is maintained, but positioning precision requirements increase
Solution Approach 1:
Stiffening elements are pre-positioned and secured within each tyre base layer length during the initial manufacturing process, rather than being aligned manually during joining. This preliminary positioning ensures precise placement before the joining operation, reducing the precision requirements during the actual join process.
Solution Approach 2:
All end portions are manufactured with identical stiffening element configurations and spacing, creating standardized interfaces that naturally align when joined. This equipotential design reduces positioning precision requirements by ensuring that matching features on each end portion guide correct alignment automatically during the joining process.
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 method enhances manufacturing efficiency by reducing manual labor and streamlining the process, resulting in a stronger and more durable tyre base layer with improved stress conduction and reduced visibility of the join.
Implementation Method 1
joining together the first end portion and the second end portion
Implementation Method 2
joining together the first end portion and the second end portion
Data Source
AI summary
A method of providing a join between a first tyre base layer end portion and a second tyre base layer end portion, the method comprising: providing a first length of tyre base layer comprising a first end portion, a first main portion, and a first pair of stiffening elements; providing a second length of tyre base layer comprising a second end portion, second main portion and a second pair of stiffening elements; joining together the first end portion and the second end portion such that each of the stiffening elements of the first pair of stiffening elements align with a corresponding stiffening element of the second pair of stiffening elements.