Rubber Crawler Tension Member Deformation Prevention
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Solution Overview
Problem
In conventional rubber crawler manufacturing, unvulcanized rubber with protrusions is molded, leading to fluid rubber flow that can deform tension members, as the low-pressure areas within the mold receive excess rubber, causing structural issues during vulcanization.
Innovation Solution
The method involves forming rubber protrusions and a main body with half-vulcanized surfaces, allowing them to be integrated without a mold, by keeping specific surfaces in a half-vulcanized state and then vulcanizing them together at high temperature and high pressure, thereby preventing deformation of tension members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If unvulcanized rubber is molded with protrusions in a conventional vulcanization process, then the rubber protrusions and main body are integrally shaped, but fluid rubber flows from high-pressure to low-pressure parts causing deformation of tension members
Solution Approach 1:
The patent applies preliminary vulcanization to form rubber protrusions before final assembly. The protrusions are pre-vulcanized to a predetermined vulcanization degree, making them solid and non-fluid, so they cannot flow and deform tension members during subsequent handling and assembly operations
Solution Approach 2:
The manufacturing process is divided into separate stages: first forming rubber protrusions independently with preliminary vulcanization, then assembling them with the main body in a subsequent vulcanization step. This segmentation prevents the harmful fluid flow effect while achieving integral shaping through the multi-stage process
2Shape
If unvulcanized rubber is kept fluid during molding to allow flow into recesses for shaping protrusions, then protrusions can be formed, but tension members are pushed and deformed by the flowing rubber
Solution Approach 1:
The patent performs preliminary vulcanization to form protrusions before final assembly. This preliminary solidification prevents the rubber from flowing and pushing against tension members, while still allowing protrusion formation in the first stage
Solution Approach 2:
The patent controls the vulcanization degree as a parameter, keeping it at a predetermined level (not complete) during the protrusion formation stage. This partial vulcanization state allows subsequent assembly while preventing harmful fluid flow that would deform tension members
3Stability of the object's composition
If complete vulcanization is performed early to prevent rubber flow, then tension members remain undeformed, but the rubber loses fluidity needed for integral shaping
Solution Approach 1:
The patent uses preliminary vulcanization to create a stable, non-fluid state in the protrusions before assembly, preventing tension member deformation. The integral shaping is then achieved in a second vulcanization step that bonds the pre-formed protrusions to the main body
Solution Approach 2:
The vulcanization process is segmented into two distinct stages: preliminary vulcanization for forming stable protrusions, and final vulcanization for integral shaping and bonding. This segmentation resolves the contradiction by achieving both stability and integral shaping through sequential processes
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 effectively suppresses deformation of tension members during manufacturing by ensuring even vulcanization and eliminating the need for a mold, improving adhesion strength and operational efficiency.
Implementation Method 1
forming rubber protrusions having a half-vulcanized surface by vulcanizing an unvulcanized rubber while keeping a part of its surface in a half-vulcanized state
Implementation Method 2
the rubber protrusions and the main body are vulcanized in a space controllable at high temperature and high pressure
Implementation Method 3
the rubber protrusions and the main body are vulcanized in a space controllable at high temperature and high pressure
Data Source
AI summary
Provided is a method for producing a rubber crawler capable of suppressing deformation of tension members which probably occurs during the manufacture. The method for producing a rubber crawler 1 comprises: obtaining rubber protrusions 4, 5 having half-vulcanized surfaces 4a, 5a by vulcanizing an unvulcanized rubber RR while keeping a half-vulcanized state; obtaining a main body 2 having half-vulcanized surfaces 2c, 2d by vulcanizing an unvulcanized rubber RR with tension members 3 embedded therein while keeping a half-vulcanized state; and arranging the rubber protrusions 4, 5 on the main body 2, and then integrating the rubber protrusions 4, 5 and the main body 2 by vulcanizing the same.