Cord-Reinforced Elastomer Band Extrusion for Precise Cord Packing
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Solution Overview
Problem
Existing methods for manufacturing cord-reinforced elastomer composition bands face challenges in achieving high-quality bands with accurately positioned cords and dense cord packing, which are difficult to achieve with prior art methods.
Innovation Solution
A method involving the extrusion of an elastomer composition onto parallel cords in a first zone, while moving the band formation in parallel to the cords, and holding the cords at a constant distance in a second zone, allowing for precise positioning and dense packing of cords.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cords are coated from two sides with flat milled sheets of rubber material using a calendar unit, then the manufacturing process is simple and well-established, but the cord positioning accuracy and cord packing density cannot be achieved
Solution Approach 1:
The manufacturing process is divided into distinct zones: a first zone for extruding elastomer composition onto parallel cords to form a first end portion, and a second zone for holding cords at constant distance. This segmentation allows precise control of cord positioning in each zone, achieving high manufacturing precision while managing process complexity through modular zone design.
Solution Approach 2:
A second cord guide is introduced as an intermediary element that slides through the elongated channel to hold cords at constant distance in the second zone. This intermediary device enables precise cord positioning and dense cord packing without requiring complete redesign of the entire manufacturing system, thus improving precision while controlling overall complexity.
2Manufacturing precision
If cords are held at constant distance in a second zone moving with the band, then dense cord packing is achieved, but the manufacturing process becomes more complex
Solution Approach 1:
The second cord guide is designed to slide through the elongated channel and move together with the first end portion of the cord-reinforced band. This dynamic arrangement allows the cord guide to maintain constant distance between cords while accommodating the continuous movement and formation of the band, achieving dense cord packing through controlled motion rather than static positioning.
Solution Approach 2:
The extrusion process continues continuously as the first end portion of the band moves away from the first zone. The second cord guide maintains constant cord spacing throughout this continuous process, ensuring dense cord packing is achieved consistently without interruption or discrete positioning steps, thereby improving packing density while managing process complexity through continuous operation.
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 enables the production of high-quality cord-reinforced elastomer composition bands with accurate cord positioning and high-volume fraction cord packing, enhancing the reliability and quality of tire manufacturing.
Implementation Method 1
starting extruding at least one elastomer composition onto the parallel cords in a first zone to form a first end portion of the cord-reinforced elastomer composition band
Data Source
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AI summary
A method of manufacturing a cord-reinforced elastomer composition band is disclosed. The method comprises: providing multiple parallel cords; extruding an elastomer composition onto the cords in a first zone to form a first end portion of the band; extruding the elastomer composition onto the parallel cords in the first zone while moving the first end portion of the band in parallel to the cords and away from the first zone; and holding the parallel cords at a constant distance relative to one another in a second zone which is adjacent and downstream the first end portion and which moves with the first end portion of the band in parallel to the cords and away from the first zone. Also, a machine for manufacturing an elastomer composition band reinforced by multiple parallel cords is disclosed. The machine comprises: an elongated channel for forming the band; a first cord guide for slidingly guiding the cords in parallel and spaced apart from one another into the channel; a die for extruding the elastomer composition into the channel to cover the cords; and a second cord guide for guiding the cords in parallel and spaced apart from one another. The second cord guide is adapted to slide through and along the elongated channel.