Dual-Layer Wire Assembly Reconfiguration for Tire Reinforcement
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Solution Overview
Problem
Existing methods for manufacturing tire reinforcement assemblies using a transitional core reduce the number of metal wire elements, leading to a decrease in linear mass and reinforcement, compromising geometric and mechanical properties.
Innovation Solution
A method involving a dual-layer assembly with inner and outer layers of helically wound metal wire elements around a transitional core, allowing for separation and reassembly to maintain high linear mass while achieving desired geometric characteristics and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of metal wire elements is reduced to provide exit passages for the transitional core, then the geometric characteristics and mechanical properties of individual wire elements are improved, but the linear mass and reinforcement of the final assembly are reduced
Solution Approach 1:
The transitional assembly is divided into multiple final assemblies by separating it into a first split assembly and a second split assembly. This segmentation allows the wire elements to be distributed across multiple final assemblies, maintaining high linear mass in each while still providing exit passages for the transitional core during the splitting process.
Solution Approach 2:
The invention transitions from a single-layer transitional assembly to a multi-layer final assembly structure. By organizing wire elements into multiple layers (inner layer and outer layer) in the final assemblies, the system achieves both sufficient linear mass and proper geometric characteristics without requiring reduction in wire element count.
2Strength
If the number of metal wire elements is increased to maintain high reinforcement, then the linear mass and reinforcement of the final assembly are improved, but the geometric characteristics and mechanical properties of individual wire elements deteriorate
Solution Approach 1:
The transitional assembly is segmented into multiple final assemblies, each receiving a portion of the wire elements. This ensures that each final assembly achieves the desired reinforcement level through adequate wire element count while the segmentation process itself enables proper geometric characteristics by allowing controlled separation and reassembly.
Solution Approach 2:
The multi-layer structure of the final assemblies (with inner and outer layers) allows for optimized wire element distribution. This dimensional organization enables each wire element to achieve proper geometric characteristics while collectively providing high reinforcement through the combined effect of multiple layers.
3Manufacturing precision
If mechanical tools are used for pre-forming wire elements, then the geometric characteristics can be controlled, but pre-forming marks and defects are introduced that reduce endurance
Solution Approach 1:
The transitional core serves as an intermediary object during the pre-forming process. Wire elements are pre-formed by wrapping around the transitional core rather than using mechanical tools, which eliminates direct mechanical contact that causes pre-forming marks and defects. The transitional core mediates the shaping process, providing the necessary geometric characteristics without introducing harmful surface defects.
Data Source
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AI summary
The method enables the production of a final assembly (A) comprising two layers and comprises a step (100) of providing a temporary assembly (AT) comprising a temporary core (NT), a step (124) of separating the temporary assembly (AT) into a first divided assembly (AF1), a second divided assembly (AF2), a third divided assembly (AF3) and the temporary core (NT). The method comprises a step (135) of reassembling the first divided assembly (AF1), the second divided assembly (AF2) and the third divided assembly (AF3) to form the final assembly (A).