Rubber Strip Forming Apparatus with Heated Rollers and Channel Die
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing rubber strips for tire building are costly and inefficient, requiring expensive equipment like gear pumps and extruders that can overheat or overwork the rubber, and lack effective control over stitching pressure.
Innovation Solution
A method and apparatus using a support frame with spaced, heated rollers and an application roller with a channel and die, allowing for adjustable temperature and speed control, and a rotating application roller with conical sides to form a rubber strip efficiently, reducing capital and energy costs while improving product quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If expensive equipment such as gear pumps and extruders are used to produce rubber strips, then the rubber strip production capability is achieved, but the capital cost and energy consumption increase significantly
Solution Approach 1:
The invention extracts and eliminates the expensive gear pump and extruder components from the rubber strip production system. Instead, it uses a simple roller apparatus where rubber stock is fed between rollers and formed into strips, removing the high-energy-consuming elements while maintaining production capability
Solution Approach 2:
The invention replaces expensive, complex equipment with simple, inexpensive roller components that can be easily manufactured and replaced. The roller apparatus uses basic mechanical elements rather than costly extrusion equipment, reducing both capital and operational costs
2Productivity
If extruders operate at very high pressure to form rubber strips, then the rubber strip formation is achieved, but the rubber material may be overworked or overheated
Solution Approach 1:
The invention replaces the high-pressure extrusion mechanical system with a low-pressure roller-based mechanical system. Instead of forcing rubber through an extruder at high pressure, the rubber is gently fed between rollers that form it into strips, eliminating the harmful high-pressure effects while achieving the desired formation
Solution Approach 2:
The invention changes the operating parameters from high pressure and high temperature (extrusion conditions) to low pressure and controlled temperature (roller feeding conditions). This parameter change prevents overheating and overworking of the rubber material while still achieving strip formation
3Productivity
If conventional extrusion equipment is used to produce rubber strips, then rubber strip production is achieved, but the stitching pressure control is insufficient
Solution Approach 1:
The invention incorporates feedback mechanisms through the roller apparatus design, where the rollers are positioned and pressured to provide consistent, controlled feeding of rubber stock. This allows for precise control of the stitching pressure as the rubber passes through the roller gap and is formed into strips
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
The solution significantly reduces capital and energy costs, allows for precise control of stitching pressure, and produces higher quality rubber strips with reduced trapped air, enabling direct reinforcement application without pre-calendering, thus enhancing the tire building process.
Implementation Method 1
The first and second rollers are preferably heated, more preferably heated at different temperatures
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An apparatus for forming a strip of rubber is disclosed. The apparatus (100) comprises a support frame (110); at least a first and a second roller (160, 170) mounted on the support frame (110), wherein the first and second rollers are spaced apart from each other; and an application roller (230) located adjacent a milltruder head (220, 400) and a channel (240) formed in a space between the milltruder head (220, 400) and an outer surface of the application roller (230). The channel (240) has an inlet and an outlet. The inlet is located in proximity to the second roller (170). The outlet is located adjacent a die (250). Also, a method of forming a rubber strip is disclosed comprising threading a rubber stock about the first and the second roller (160, 170) and then through a channel (240) formed between a head (220, 400) and a rotating application roller (230) and then through an outlet die (250).