Continuous Gum Strip Crosswinding Without Extruder Stops
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Solution Overview
Problem
Current methods for manufacturing rubber tires are restrictive due to handling and storage challenges, yield loss, and inefficiencies in the winding and unwinding processes, particularly related to the stopping of the extruder.
Innovation Solution
A continuous process and installation for winding strips of rubber around reels, involving continuous scrolling and cooling of the rubber web, deposition on a support film, cutting into strips, and spooling without stopping the extruder, with automated reel replacement and speed control to optimize production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the extruder is stopped for separate winding operations, then the rubber web can be wound into reels, but production continuity is lost and yield is reduced
Solution Approach 1:
The patent merges the winding operation with the extrusion process by integrating a spooling unit directly into the extruder output. The rubber web is wound onto spools continuously as it exits the extruder, eliminating the need to stop the extruder for separate winding operations. This integration maintains production continuity and eliminates yield loss associated with stopping and restarting the extruder.
Solution Approach 2:
The patent implements continuous winding of the rubber web onto spools as it exits the extruder, maintaining uninterrupted production. The spooling unit operates continuously alongside the extruder, ensuring that the rubber web is immediately wound onto spools without pauses or interruptions to the extrusion process, thereby preserving production continuity and eliminating idle time.
2Ease of manufacture
If the extruder is stopped for winding operations, then reels can be manufactured, but handling and storage requirements increase
Solution Approach 1:
The patent combines the extrusion and winding functions into a single integrated system. The spooling unit is positioned directly at the extruder output, allowing the rubber web to be wound onto spools immediately as it exits the extruder. This eliminates the need for separate handling, transport, and storage systems that would be required if the extruder stopped for winding operations.
3Productivity
If separate winding operations are performed, then reels can be produced, but yield loss occurs due to extruder stopping
Solution Approach 1:
The patent maintains continuous operation of the extruder while simultaneously winding the rubber web onto spools. The spooling unit operates in parallel with the extruder, ensuring that no rubber is lost during transitions or idle periods. This continuous process eliminates the yield loss that would occur if the extruder had to stop for separate winding operations.
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
Enables continuous production of rubber strips without the need for separate winding operations, improving efficiency and reducing handling and storage requirements, allowing for uninterrupted extruder operation and optimal performance.
Implementation Method 1
scrolling and cooling the web at the outlet of the extruder by means of transitic and cooling rollers
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
Method and facility for continuously crosswinding gum strips about spools. The method of the invention comprises the following consecutive steps: - continuously feeding out and cooling the web (5) from the outlet of the extruder (6) via handling and cooling rollers (7a); continuously depositing the cooled web (5) on a liner (9) that is continuously unwound to form a complex (10); feeding the complex (10) into an accumulator (12); at the outlet of the accumulator (12), cutting the complex (10) into a plurality of strips (2) in the direction of its width; crosswinding, at an initial speed, each strip about a spool.