Narrow Topping Sheet Formation via Weft Yarn Cutting
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Solution Overview
Problem
Existing methods for forming a narrow topping sheet for pneumatic tire carcass ply production are inefficient, requiring complex production control and labor-intensive processes, and often result in equipment constraints and increased production costs.
Innovation Solution
A method and apparatus that feed and divide a wide textile original fabric into narrow sections using a wire with a constant tensile force, allowing simultaneous feeding and cutting of weft yarns without damaging warp yarns, and then topping the narrow sections with unvulcanized rubber to form a narrow topping sheet, eliminating the need for a separate cord original fabric preparation step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a wide textile original fabric is topped with unvulcanized rubber and then divided widthwise, then a narrow topping sheet can be formed, but the topping process becomes complex and calender lines increase in size
Solution Approach 1:
The patent divides the textile original fabric into multiple narrow sections before the topping process by cutting the weft yarns. This segmentation allows each narrow section to be topped independently, simplifying the topping process and reducing calender line size requirements while maintaining the ability to form narrow topping sheets with precise dimensions
2Manufacturing precision
If tire cords are supplied from a large number of cord bobbins to form a narrow cord original fabric, then a narrow topping sheet can be formed, but labor is required to set the large number of cord bobbins
Solution Approach 1:
The patent merges multiple cord supplies into a single wide textile original fabric that is then divided into narrow sections. This approach eliminates the need to handle and set up numerous individual cord bobbins, as the wide fabric can be fed from a single source and divided automatically during the topping process, significantly reducing setup labor while maintaining narrow topping sheet production
3Area of stationary object
If the topping sheet width is narrowed to about 0.5 m to facilitate direct supply to molding step, then equipment space is saved, but the topping process becomes more difficult
Solution Approach 1:
The patent performs the division of the textile original fabric into narrow sections as a preliminary action before the topping process. By pre-dividing the fabric widthwise and cutting the weft yarns, the subsequent topping process becomes easier as it only needs to handle narrow sections, allowing the use of compact topping equipment with reduced space requirements while maintaining manufacturing ease
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
This approach enables efficient formation of narrow topping sheets, reduces production costs, and optimizes equipment space usage by directly supplying the narrow textile original fabric for topping, thereby simplifying the production process.
Implementation Method 1
a feeding and division step of feeding a textile original fabric, obtained by weaving longitudinally aligned tire cords into a cord fabric by use of weft yarns, and cutting off the weft yarns in predetermined widthwise positions to divide the textile original fabric into a plurality of narrow textile original fabrics
Implementation Method 2
a topping step of topping at least one surface of each of the narrow textile original fabrics with unvulcanized rubber
Data Source
AI summary
A topping sheet forming method includes: a feeding and division step of feeding a textile original fabric, obtained by weaving longitudinally aligned tire cords into a cord fabric by use of weft yarns, and cutting off the weft yarns in predetermined widthwise positions to divide the textile original fabric into a plurality of narrow textile original fabrics; and a topping step of topping at least one surface of each of the narrow textile original fabrics with unvulcanized rubber.