Corrugated Thermoplastic Airtight Layer for Deformable Tires
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Solution Overview
Problem
Existing airtight layers in tires face challenges in achieving both effective airtightness and deformability while minimizing hysteresis, with known solutions being complex and costly, and thermoplastic films used in tires suffer from poor deformability and high manufacturing complexity.
Innovation Solution
A method involving a thermoplastic film with corrugations, coated in an elastomer matrix, where the film is heated, corrugated, and cooled to form a composite airtight layer with specific thickness and corrugation characteristics, enhancing deformability and airtightness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermoplastic film is used to form an airtight layer, then airtightness is improved and hysteresis is reduced, but deformability deteriorates and manufacturing complexity increases
Solution Approach 1:
The thermoplastic film is divided into multiple small fragments rather than using a continuous film. These fragments are dispersed within the elastomer matrix, allowing the structure to deform while maintaining airtightness through the collective barrier effect of numerous small pieces rather than a single continuous layer.
Solution Approach 2:
The invention creates a composite structure combining thermoplastic film fragments with elastomer matrix material. This composite approach allows the airtight layer to exhibit both the low permeability and low hysteresis of thermoplastics and the high deformability of elastomers, resolving the contradiction between airtightness and adaptability.
2Loss of energy
If a thermoplastic film is used to form an airtight layer, then hysteresis is reduced, but manufacturing complexity and cost increase
Solution Approach 1:
The invention uses inexpensive thermoplastic film fragments that can be easily produced and incorporated into the elastomer matrix. These fragments serve their airtight function effectively without requiring complex processing or expensive materials, reducing both manufacturing complexity and cost while maintaining low hysteresis.
3Adaptability or versatility
If butyl rubber is used for the airtight layer, then deformability is maintained, but hysteresis losses increase and airtightness deteriorates
Solution Approach 1:
The composite structure combines elastomer matrix (providing deformability) with thermoplastic film fragments (providing low hysteresis and airtightness). This allows the airtight layer to achieve properties superior to pure butyl rubber by leveraging the complementary strengths of both material types.
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
The composite airtight layer provides improved airtightness and deformability, reducing hysteresis and manufacturing complexity, forming a continuous barrier against gas diffusion while maintaining flexibility and durability.
Implementation Method 1
a film made of thermoplastic material is heated such that the film is able to plastically deform
Implementation Method 2
the film is cooled such that the corrugated film is no longer able to be plastically deformed
Data Source
AI summary
A method for manufacturing a composite airtight layer (20) used in the composition of a tire (30) comprises: a film (21) made of thermoplastic material is heated such that the film is able to plastically deform; the film is deformed (120) with the aid of corrugating means, the thickness of the film (21) being in a range from 0.01 to 0.2 mm, and the film having corrugations with a pitch and amplitude chosen in a range from 0.1 to 10 mm so as to give the film a given elongation capacity; the film is cooled such that the corrugated film is no longer able to be plastically deformed; and the corrugated film is coated in a matrix (22) of elastomer material, so as to form a composite airtight layer (20).