Elastomer Composite Monofilament Winding to Reduce Shape Defects
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Solution Overview
Problem
Existing methods for manufacturing elastomeric composites with metallic monofilaments result in significant shape defects due to plastic deformation during storage on standard spools, making automated installation difficult and reducing industrial productivity.
Innovation Solution
The method involves winding metallic monofilaments onto spools with a hub radius greater than 59 mm, ensuring the monofilaments are arranged parallel and embedded in an elastomer matrix, reducing plastic deformation and shape defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If monofilaments are wound on standard spools with hub radius of 59 mm, then the spool dimensions are standardized and space-efficient, but the monofilaments undergo significant plastic deformation causing bend and shape defects
Solution Approach 1:
The patent changes the critical parameter of hub radius from the standard 59 mm to a larger value of at least 76 mm. This parameter change reduces the curvature imposed on the monofilament during winding, thereby minimizing plastic deformation and bend while still maintaining practical spool dimensions for storage and transport.
2Ease of manufacture
If monofilaments are stored on spools, then they can be conveniently stored and transported, but they develop bend and shape defects that complicate automated installation
Solution Approach 1:
By increasing the hub radius parameter to at least 76 mm, the patent maintains the convenience of spool-based storage and transport while reducing the bend and shape defects to levels that enable automated installation processes to function effectively.
3Quantity of substance
If monofilaments are wound tightly on spools to maximize storage capacity, then more monofilament can be stored, but the plastic deformation and bend increase
Solution Approach 1:
The patent changes the hub radius parameter to at least 76 mm, which allows for adequate monofilament storage capacity while reducing the curvature-induced plastic deformation. The larger radius provides a gentler bending path that minimizes bend even when spools are fully wound.
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 approach significantly reduces shape defects such as undulations and twists, enabling efficient automated installation of reinforced plies in tire manufacturing.
Implementation Method 1
Storing monofilament on a spool causes plastic deformation of the monofilament. In fact, the path formed by the monofilament, unwound from the spool after storage and free of any external stress, is slightly curvilinear.
Data Source
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AI summary
The invention concerns a method (200) for manufacturing an elastomer composite, which comprises the following steps: winding (130) a plurality of metal monofilaments (30) of circular cross-section and diameter Df in the range from 0.05 mm to 6 mm on a plurality of storage reels (20), each reel comprising a hub (22) defining a cylindrical jig (62) with radius of curvature Rm greater than 59 mm, each metal monofilament (30) being wound around a hub (22); storing (140) the plurality of reels, each reel comprising a winding of a metal monofilament (30); unwinding (210) the plurality of metal monofilaments from the plurality of reels; disposing (220) the plurality of metal monofilaments parallel to each other; and, immersing (230) the plurality of metal monofilaments in an elastomer matrix so as to form the elastomer composite.