Rubber Component Production with Embedded Electronics
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Solution Overview
Problem
Existing methods for producing rubber components with embedded electronic assemblies, such as RFID chips, are inefficient for on-demand production due to high capital requirements and inflexibility in responding to fluctuating demand.
Innovation Solution
A method involving stationarily positioning a lower ply of rubber material with an embedded electronic assembly and unrolling and adhesively connecting a top ply in a cyclic, counter-directional process, allowing for flexible and efficient production of rubber components with embedded electronic assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a continuous production method is used to produce rubber components with embedded electronic assemblies, then high output and productivity are achieved, but high capital requirements and inflexibility for fluctuating demand result
Solution Approach 1:
The patent implements periodic action by alternating between feeding the lower ply in the production direction and unrolling the upper ply in the opposite direction. This cyclic, discontinuous process allows the system to produce components on-demand rather than continuously, enabling flexibility for fluctuating demand while maintaining efficient production cycles
2Productivity
If a continuous production method is used to produce rubber components with embedded electronic assemblies, then high output is achieved, but device complexity and capital requirements increase
Solution Approach 1:
The patent applies segmentation by dividing the production process into distinct sequential stages: feeding the lower ply with electronic assemblies, stationarily positioning it, unrolling the upper ply in the opposite direction, and adhesively connecting the plies. This segmented approach simplifies the overall system compared to continuous production while maintaining effective output
3Ease of manufacture
If the upper ply is unrolled in the production direction, then the process is simplified, but the electronic assemblies cannot be properly embedded between the plies
Solution Approach 1:
The patent applies inversion by unrolling the upper ply in the direction opposite to the production direction. This counter-intuitive approach allows the upper and lower plies to be adhesively connected with the electronic assemblies properly embedded between them, as the plies move in opposite directions during the lamination process before being conveyed forward together
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 cost-effective production of rubber components with embedded electronic assemblies, suitable for various applications, including tires, by discontinuously laminating the rubber plies while allowing for cyclic production and easy separation into individual components.
Implementation Method 1
fixedly adhesively connecting the length portions of the plies of the rubber material so as to embed the at least one electronic assembly
Data Source
AI summary
The invention relates to a method for producing a rubber component (1), in the case of 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) providing a length portion of the lower ply (10) of the rubber material, which is equipped, on the top side (100), with at least one electronic assembly (2);b) stationarily positioning the length portion of the lower ply (10);c) unrolling a length portion of the upper ply (11) of the rubber material on the top side (100) of the stationary length portion of the lower ply (10) in an unrolling direction (A), and fixedly adhesively connecting the length portions of the plies (10, 11) of the rubber material so as to embed the at least one electronic assembly (2);d) conveying out the length portion of the rubber component (1).A corresponding device for producing the rubber components (1) is also specified.