Hybrid Induction-Nitrogen Tire Curing Without Steam
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Solution Overview
Problem
Traditional tire curing methods using steam are inefficient, costly, and difficult to control, leading to sub-optimal production times and energy waste, particularly in locations where water is scarce or prioritized for other uses.
Innovation Solution
A hybrid electromagnetic induction-nitrogen heating system that uses induction coils and pressurized nitrogen gas to cure tires without water, allowing independent control of heat and pressure parameters for efficient curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If steam is used for tire curing, then heat energy can be supplied to the tire, but steam energy cost is high and steam is difficult to contain and deliver
Solution Approach 1:
The patent replaces the traditional steam-based heating system with an electromagnetic induction heating system. Induction coils generate electromagnetic fields that directly induce eddy currents in the tire, converting electrical energy to thermal energy without requiring steam generation, piping, or containment infrastructure. This substitution eliminates the harmful factors associated with steam while maintaining effective heat supply.
Solution Approach 2:
The patent introduces electromagnetic fields as an intermediary between the power source and the tire. The induction coils convert electrical energy to electromagnetic fields, which then induce eddy currents in the tire, creating a direct energy transfer pathway that bypasses the need for steam as a thermal mediator.
2Temperature
If steam is used for tire curing, then heat energy can be supplied to the tire, but maintenance effort leads to long downtimes
Solution Approach 1:
The patent replaces the complex steam generation and delivery mechanical system with a simpler electromagnetic induction system. The induction coils have no moving parts, no water treatment requirements, and no piping infrastructure, thereby eliminating maintenance activities that cause downtime and enabling continuous operation.
3Stress or pressure
If pressurized steam is used to force tire into mold, then shaping can be achieved, but not all process parameters can be adjusted independently
Solution Approach 1:
The patent segments the heating and pressuring functions into independent systems. The electromagnetic induction system controls heating parameters independently, while the nitrogen gas system controls pressure and shaping parameters independently. This segmentation allows each parameter to be adjusted without affecting the other, providing full adaptability.
Solution Approach 2:
The patent introduces nitrogen gas as a separate intermediary for pressure application and shaping, independent of the heating system. This allows pressure and temperature parameters to be controlled independently, as the nitrogen system does not rely on steam generation and can be adjusted separately from the induction heating parameters.
4Temperature
If steam is used for tire curing, then heat energy can be supplied to the tire, but antioxidants must be added to protect bladder from steam deterioration
Solution Approach 1:
The patent replaces the steam-based heating system with an electromagnetic induction system that uses electromagnetic fields to generate heat directly in the tire. This eliminates the harmful chemical interactions between steam and the bladder material, removing the need for antioxidants and extending bladder service life.
Solution Approach 2:
The patent uses nitrogen gas in an inert atmosphere to provide pressure and support the bladder during curing. The inert nitrogen environment prevents oxidative deterioration of the bladder, eliminating the need for chemical protectants while maintaining a safe operating environment.
5Temperature
If condensing steam is used for tire curing, then heat energy can be transferred to the tire, but local overheating occurs that negatively affects tire performance
Solution Approach 1:
The patent replaces the steam condensation heating mechanism with electromagnetic induction heating. The induction coils generate electromagnetic fields that induce eddy currents throughout the tire, producing heat uniformly across the entire tire surface without the localized overheating that occurs with steam condensation.
Solution Approach 2:
The electromagnetic fields induce eddy currents that create internal heating through resistive heating effects. This internal heat generation mechanism distributes thermal energy uniformly throughout the tire structure, avoiding the external heat transfer issues that cause localized overheating in steam-based systems.
6Productivity
If traditional steam curing process is used, then tires can be cured, but production time is not optimized and heat energy is wasted
Solution Approach 1:
The patent replaces the inefficient steam-based curing system with electromagnetic induction heating, which transfers energy directly to the tire through electromagnetic fields. This eliminates energy losses in steam generation, piping, and heat transfer, achieving near 100% energy efficiency and reducing cure time by eliminating the thermal inertia of steam-based systems.
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
Reduces cure time by up to 20% and eliminates the need for steam, improving energy efficiency and reducing water consumption while maintaining tire performance.
Implementation Method 1
a mold platen including a first induction coil, the first induction coil configured to produce a first electromagnetic field to induce a first eddy current in the mold platen and a mold jacket including a second induction coil, the second induction coil configured to produce a second electromagnetic field to induce a second eddy current in the mold jacket
Implementation Method 2
A first heat energy generated by the first eddy current induced in the mold platen is transferred to the mold and the tire. A second heat energy generated by the second eddy current induced in the mold jacket is transferred to the mold and the tire
Implementation Method 3
A third heat energy from the heated pressurized nitrogen gas is transferred to the bladder and the tire
Implementation Method 4
A third heat energy from the heated pressurized nitrogen gas is transferred to the bladder and the tire
Data Source
AI summary
A waterless tire curing system for curing a tire in a mold includes a platen and a mold jacket configured to have at least one component of the mold coupled thereto. The platen and the mold jacket include an induction coil. An electric coil is provided that produces an electromagnetic field to induce an eddy current into the induction coil to produce a first heat energy. A bladder is disposed in an interior of the mold and a nitrogen supply system is included to provide a heated pressurized nitrogen gas for circulation through the bladder. The heat energy from the induction coil is transferred to the mold and the uncured tire. The heat energy from the heated pressurized nitrogen gas is transferred to the bladder and the uncured tire, wherein the heat energy transferred to the uncured tire is effective to cure the tire.