Multi-ply Laminate Transfer for Tire Reinforcement
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Solution Overview
Problem
Existing tire manufacturing methods face inefficiencies due to the need for sequential transfer of reinforcing plies, which reduces output and requires manual intervention for accurate welding, leading to difficulties in automation and increased footprint of manufacturing installations.
Innovation Solution
A method involving the simultaneous transfer of two pre-formed plies on the same support, where one ply overlaps the other, allowing for a single transfer operation and improved control of ply positioning and welding, enabling automated and compact tire manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sequential transfer of individual plies is used, then each ply can be transferred separately to the building support, but the laying tool output is reduced due to interruption time required to remove and free the assembly support
Solution Approach 1:
The patent combines multiple plies into a single laminate structure that is transferred as one unit. The assembly support transfers the entire laminate (containing multiple plies) to the building support in a single operation, eliminating the need to remove and reposition the assembly support between individual ply transfers. This merging of transfer operations restores continuous production and maximizes laying tool output.
Solution Approach 2:
The patent performs preliminary assembly of multiple plies into a complete laminate on the assembly support before transfer. By pre-forming the multi-ply laminate structure in advance, the system eliminates subsequent interruption times that would occur if plies were transferred individually. The preliminary consolidation of plies enables uninterrupted continuous transfer operations.
2Ease of manufacture
If multiple separate work stations are provided for assembling and transferring plies, then the manufacturing process can be completed, but the installation footprint becomes relatively large
Solution Approach 1:
The patent merges the functions of multiple separate work stations into a single integrated assembly support system. The assembly support performs both ply assembly and transfer operations in one location, eliminating the need for separate stations for each function. This consolidation significantly reduces the installation footprint while maintaining complete manufacturing capability.
Solution Approach 2:
The assembly support is designed as a multi-functional device that combines ply laying, ply assembly into laminates, and transfer to the building support. This universal device performs multiple operations that previously required separate specialized stations, thereby reducing the overall space requirement while maintaining full manufacturing functionality.
3Reliability
If manual intervention is used for welding ply edges, then weld quality can be ensured, but automation of the manufacturing process becomes difficult
Solution Approach 1:
The patent segments the welding operation from the transfer operation by positioning the laminate on the assembly support such that ply edges are pre-aligned and accessible. The laminate structure is divided into transferable body and weldable edges, allowing automated welding systems to access and join edges without requiring manual intervention, thereby enabling full process automation while maintaining weld quality.
Solution Approach 2:
The patent replaces manual welding operations with automated welding systems. By designing the laminate structure and transfer mechanism to facilitate automated edge access and positioning, the system substitutes human-operated welding with automated welding technology, achieving both high weld quality and complete process automation.
Data Source
AI summary
A first ply and then a second ply, which is superposed on the first ply, are produced on a hoop-type first support. The hoop-type first support has a first receiving surface, to form a laminate. The first and second plies forming the laminate are transferred onto an annular second receiving surface of a core so that the laminate is wrapped on the core until each ply is closed on itself and the laminate is thus closed on itself in a ring about the central axis of the core.