Mold Cleaning Cover Production via Rubber Strip Winding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current mold cleaning methods for tire vulcanization molds are inefficient, requiring mold removal for shot blast or laser cleaning, or leaving contaminants behind with dry ice methods, and existing rubber compositions for mold cleaning lack flexibility and uniformity, leading to suboptimal cleaning results.
Innovation Solution
A production method involving the application of an unvulcanized rubber composition on tire covers using a rubber strip winding step for side walls and tread shoulders, and a plate-like rubber material winding step for the tread center, allowing for vulcanization without mold removal and ensuring a uniform rubber layer with a gauge of at least 1.0 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If shot blast or laser cleaning is used, then mold cleaning effect is improved, but mold must be removed from vulcanizer causing time loss
Solution Approach 1:
The rubber composition performs self-cleaning function by transferring contaminants from the mold surface during the vulcanization process itself, eliminating the need for separate cleaning operations and mold removal
Solution Approach 2:
The cleaning function is merged with the tire vulcanization process - the same rubber composition that forms the tire cover also serves as the cleaning medium, combining two functions into one process
2Reliability
If dry ice cleaning is used, then mold cleaning is achieved, but contaminants remain in mold and attach to tire
Solution Approach 1:
The rubber composition converts the harmful contaminants on the mold surface into a beneficial cleaning mechanism - the contaminants are transferred to the rubber composition which then carries them away from the mold, preventing re-deposition on the tire
Solution Approach 2:
The rubber composition acts as an intermediary medium between the mold surface and the tire, absorbing contaminants from the mold and preventing their transfer to the tire during the vulcanization process
3Reliability
If unvulcanized rubber composition is applied as sheet on raw cover, then mold cleaning is attempted, but rubber sheet does not follow cover shape causing non-uniform gauge and air biting
Solution Approach 1:
The rubber composition parameters are specifically adjusted - viscosity is reduced to enhance flexibility and conformability, allowing the rubber to adapt to the raw cover shape while maintaining uniform thickness during application
Solution Approach 2:
The rubber composition is formulated as a flexible, pliable material that can conform to the complex three-dimensional shape of the raw cover, eliminating air pockets and ensuring uniform coverage without rigid sheet limitations
4Reliability
If rubber layer gauge is increased for better cleaning, then cleaning capability improves, but production time increases
Solution Approach 1:
The rubber composition viscosity is optimized to achieve adequate gauge (1.0-3.0 mm) through controlled application rather than thick layering, allowing sufficient contaminant transfer capability while maintaining application speed and productivity
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 effective mold cleaning without removing the mold from the vulcanizer, maintaining productivity and preventing contaminant residue on the tire, while ensuring a uniform and sufficient rubber layer for efficient contaminant transfer.
Implementation Method 1
contaminants adhered on a mold by transferring the contaminants to the rubber composition
Implementation Method 2
transferring the contaminants to the rubber composition
Implementation Method 3
vulcanizing a cover for mold cleaning applied on an outer periphery of a raw cover
Data Source
AI summary
An object of the present invention is to provide a production method of a cover for mold cleaning which can clean a mold without removing the mold from a vulcanizer and is excellent in a mold cleaning effect while maintaining productivity. The production method of a cover for mold cleaning is produced by applying an unvulcanized rubber composition on an outer periphery of a raw cover, the method comprising a rubber strip winding step of winding a rubber strip consisting of the unvulcanized rubber composition from side wall portions to tread shoulder portions of a raw cover, and a plate-like rubber material winding step of applying a plate-like rubber material consisting of the unvulcanized rubber composition on a tread center portion of the raw cover, wherein a gauge of the rubber composition after vulcanization of the cover is not less than 1.O mm.