Modular Tire Mold Elements for Laser Sintering
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Solution Overview
Problem
Existing methods for manufacturing tire tread molding networks, particularly those using laser sintering, face issues with thermal deformations leading to warping and manufacturing tolerances, requiring large machines and resulting in the need to scrap entire networks if a single molding element is defective.
Innovation Solution
A set of molding elements with complex shapes that connect via generally straight interfaces, allowing for assembly into a robust mold with individual elements made from steel using laser sintering or other methods, attached to a cast aluminum body, enabling efficient and practical manufacturing with reduced warping risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If laser sintering is used to manufacture an integral network of molding elements, then complex shapes and intricate details can be achieved, but thermal deformations cause warping and manufacturing tolerances are compromised
Solution Approach 1:
The patent divides the integral network into multiple separate molding elements that are assembled together. Each element can be manufactured independently with controlled thermal deformation, and the modular design allows for compensation of warping through the assembly process, thereby maintaining manufacturing tolerances while achieving complex shapes.
Solution Approach 2:
The patent combines multiple separately manufactured molding elements into a functional network assembly. This merging approach allows each element to be optimized for laser sintering with minimal thermal distortion, while the collective assembly achieves the complex overall shape required for tire tread molding.
2Area of stationary object
If a large sized laser sintering machine with a large bed is used to manufacture the network, then the entire tread width can be covered, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent segments the large-area molding network into multiple smaller molding elements that can be manufactured on standard-sized laser sintering machines. This eliminates the need for large specialized equipment while still achieving comprehensive tread width coverage through the assembled network of elements.
3Strength
If the network is manufactured as a single integral piece, then structural integrity is maintained, but any manufacturing defect requires scrapping the entire network
Solution Approach 1:
The patent divides the molding network into multiple independent elements, so that a defect in one element does not compromise the entire network. Each element maintains its own structural integrity, and the modular design allows defective elements to be replaced individually, significantly improving reliability and reducing waste.
4Adaptability or versatility
If molding elements have complex undulated shapes to improve grip and wear resistance, then tire performance is enhanced, but manufacturing complexity and thermal deformation risks increase
Solution Approach 1:
The patent segments complex undulated molding elements into smaller modular units with simplified connection interfaces. Each element can feature the required undulated shapes for tire performance, while the segmentation reduces the overall thermal mass of each piece, minimizing thermal deformation risks during laser sintering.
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
The solution allows for the creation of a robust and complex tire tread mold network that maintains mechanical integrity and manufacturing tolerances, simplifying assembly and reducing thermal deformation issues, while enabling efficient use of laser sintering technology.
Implementation Method 1
laser sintering allows manufacturing intricate shapes
Implementation Method 2
manufacturing a tire mold using laser sintering
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention provides for a set of molding elements (4, 5) adapted to be attached in a mold for molding tires, each molding element being able to mold a cut in a tire tread, wherein the set of molding elements comprises complex shaped molding elements, each molding element being able to connect to another molding element from the set of molding elements along a generally straight interface (54) defined between connecting molding elements The invention also provides for a mold for molding tires, said mold comprising a set of molding elements as described above attached to a main cast aluminum body.