Rubber Component Lamination for Flexible Electronic Embedding
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Solution Overview
Problem
Existing methods for producing rubber components with embedded electronic components, such as RFID transponders, face challenges in achieving flexible and efficient production, particularly when on-demand production requirements fluctuate.
Innovation Solution
A method involving the intermittent application of a cut section of the upper rubber layer, shorter than the distance between electronic components, to the lower layer, followed by lamination and separation, allowing for discontinuous production and enhanced adhesion to tire layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a continuous lamination process is used with high take-off capacity, then productivity is improved, but adaptability to fluctuating on-demand production requirements deteriorates
Solution Approach 1:
The patent implements periodic action by alternating between continuous lamination mode (for high productivity when demand is high) and intermittent stopping mode (for flexibility when demand fluctuates). The device can be stopped between feeding the lower layer and applying the upper layer, allowing production to match on-demand requirements while maintaining the capability for continuous high-speed operation when needed.
2Productivity
If the upper layer is applied continuously without stopping, then productivity is improved, but ease of operation for on-demand production deteriorates
Solution Approach 1:
The patent applies dynamics by making the production process adaptable and changeable based on demand. The device transitions from a static continuous operation mode to a dynamic mode where it can be interrupted and resumed. This allows operators to easily adjust production levels by simply stopping or continuing the feeding and lamination operations, greatly improving ease of operation for on-demand production.
3Manufacturing precision
If sections of the upper layer are cut to finished size before application, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent implements preliminary action by cutting the upper layer sections to their finished size before the lamination process. This pre-cutting ensures precise dimensions and shapes are achieved, as the sections are prepared in advance with the exact required geometry. The sections are then simply applied to the lower layer during lamination, maintaining manufacturing precision without requiring complex in-line cutting mechanisms during the bonding process.
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 simple, flexible, and efficient production of rubber components with embedded electronic assemblies, ensuring robust adhesion to tire layers and compatibility with continuous or on-demand production needs.
Implementation Method 1
a section 11 of the upper layer 11 which has been cut to a predetermined finished size is applied to the electronic assembly 2 arranged at the front on the upper side 100 and adhesively connected to the lower layer 10
Data Source
Figure 1~4
AI summary
The invention relates to a method for producing a rubber component (1), according to which at least one electronic assembly (2) is embedded between a lower and an upper ply (10, 11) of a rubber material, comprising the steps: • a) feeding a strip of the lower ply (10) of the rubber material, which is provided, on its upper face (100) with electronic assemblies (2) attached at predefined distances (A), in a conveying direction (F); • b) applying a section of the upper ply (11) of rubber material, which has been cut to a predefined finished size, to the very first electronic assembly (2), viewed in the conveying direction (F), and fixedly bonding said section to the lower ply (10) of the rubber material, thereby embedding the electronic assembly (2) and forming a rubber component (1) on the leading edge, viewed in the conveying direction (F), of the lower ply (10); • c) separating the rubber component from the lower ply (10). The invention also relates to a corresponding device for producing the rubber components.