Ring-Shaped Bellows for Tire Vulcanization Closing Force Reduction
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Solution Overview
Problem
Existing tire vulcanization processes require high closing forces and complex, costly heating press constructions due to the use of pillow-like bellows, limiting the manufacturing of tires with stronger profiles and inefficiently utilizing process time for loading and unloading.
Innovation Solution
A ring-shaped bellows system with a rim-like carrier, made of elastic and solid materials respectively, reduces closing forces by up to 10% and allows for a mobile, transportable unit that optimizes loading, unloading, and vulcanization processes, enabling efficient energy use and resource management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a pillow-like bellows is used for tire vulcanization, then the tire blank can be supported and shaped, but the closing forces required increase to several hundred tons, resulting in robust and costly press construction
Solution Approach 1:
The bellows is segmented into a modular system consisting of a rigid support structure with radially expandable bellows segments. This segmentation allows the bellows to be supported at multiple points along its circumference, distributing the loading forces and reducing the closing force requirement while maintaining adequate support for the tire blank.
Solution Approach 2:
The system combines rigid support structure elements with flexible bellows components made of elastomeric materials. This composite construction allows the rigid parts to bear the closing forces while the flexible bellows provide the necessary compliance and shaping capability for the tire blank.
2Reliability
If conventional heating presses are designed with robust construction to handle high closing forces, then mechanical stability is ensured, but manufacturing costs increase significantly
Solution Approach 1:
The press structure is designed with modular, segmented components that can be manufactured separately and assembled. The rigid support structure for the bellows is divided into discrete elements that can be produced using standard manufacturing processes, reducing overall cost while maintaining the necessary mechanical stability.
3Ease of operation
If loading and unloading systems are permanently assigned to a single heating press, then tire handling is simplified, but process time efficiency decreases as 80% of time is spent on vulcanization with only 20% on loading/unloading
Solution Approach 1:
The loading and unloading systems are designed as universal, multi-functional units that can serve multiple heating presses. The bellows and carrier assembly can be transferred between presses, allowing a single loading system to handle tires for several presses sequentially, thereby improving overall process time efficiency while maintaining operational simplicity.
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
Significantly reduces manufacturing costs, enhances tire handling and quality control, and allows for efficient energy and resource use in tire production by minimizing the need for manual interventions and enabling direct quality control, while accommodating various tire sizes.
Implementation Method 1
The bellows is made of an elastic material
Implementation Method 2
the mold is heated
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to a method and to a device for vulcanizing tires. An expandable bellows is used to press the tire to be vulcanized against segments of a mold. The bellows (7) is arranged on a carrier (2) which has an annular design.