Metal Filamentary Element Assembly Separation and Reassembly
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Solution Overview
Problem
Existing methods for manufacturing final assemblies with metal filamentary elements reduce the number of elements in the layer, leading to decreased linear density and reinforcement, particularly in tires, while attempting to achieve desired geometric characteristics and mechanical properties.
Innovation Solution
A method involving the collective preforming of metal filamentary elements around a transitory core, allowing for the separation of the core and the reassembly of split assemblies to maintain high linear density and achieve desired geometric characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the number of metal filamentary elements in the layer is reduced to create extraction passages for the transitory core, then the transitory core can be separated from the final assembly, but the linear density and reinforcement of the final assembly decrease
Solution Approach 1:
The layer of metal filamentary elements is divided into multiple sub-layers, with each sub-layer containing a subset of the total elements. This segmentation allows extraction passages to be formed in each sub-layer independently, enabling transitory core separation while preserving the overall structure and linear density of the final assembly through reassembly of the sub-layers.
Solution Approach 2:
The metal filamentary elements are collectively preformed around the transitory core before separation, establishing their geometric characteristics and positioning. This preliminary action ensures that when the transitory core is removed and sub-layers are reassembled, the elements maintain their desired geometric properties and contribute to high linear density without requiring individual preforming operations.
2Quantity of substance
If a high number of metal filamentary elements are used to maintain high reinforcement, then the linear density increases, but it becomes difficult to achieve the desired geometric characteristics and mechanical properties
Solution Approach 1:
Multiple sub-layers of metal filamentary elements are combined through reassembly to form the final assembly. Each sub-layer is preformed around the transitory core with precise geometric characteristics, and the combination of these preformed sub-layers achieves both high linear density (through the total number of elements) and precise geometric characteristics (through the controlled preforming process).
Solution Approach 2:
The transitory core serves as an intermediary tool during the preforming process. It provides a reference structure that enables collective preforming of the metal filamentary elements, ensuring accurate geometric characteristics are achieved. The core is temporarily present during formation and is subsequently removed, leaving the precisely formed elements in their final configuration.
3Manufacturing precision
If mechanical tools are used to preform individual metal filamentary elements, then geometric characteristics can be achieved, but preforming marks are created that reduce the endurance of the elements
Solution Approach 1:
The metal filamentary elements perform their own preforming through collective winding around the transitory core. The helical winding process naturally imparts the desired geometric characteristics without requiring external mechanical tools that would create surface marks. The elements' own structural properties and the winding process itself achieve the geometric precision, eliminating the need for tool-induced deformation.
Solution Approach 2:
The traditional mechanical preforming system (external tools pressing or bending individual elements) is replaced by a collective winding process around a transitory core. This substitution uses the core as a formative constraint rather than external mechanical tools, achieving geometric characteristics through the winding geometry itself rather than through mechanical deformation that would create surface marks and reduce endurance.
Data Source
AI summary
The method makes it possible to manufacture an assembly (A) comprising a layer (C) of metal filamentary elements (14) wound in a helix. The method comprises a step (100) of supplying a temporary assembly (22) comprising a layer (13) of M′>1 metal filamentary elements (14) and a temporary centre (16), and a step (110) of separating the temporary assembly (22) between a first split assembly (25), a second split assembly (27) and the temporary centre (16). The method comprises a step (140) of reassembling the first split assembly (25) with the second split assembly (27) so as to form the layer (C) of the assembly (A).