Uncured Rubber Tread Cutting Joining Method
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Solution Overview
Problem
Conventional tire tread production methods are inefficient for small production runs and research testing, requiring expensive equipment and generating significant scrap material, as they necessitate the design and use of costly tooling and dies for extrusion, which is wasteful and time-consuming.
Innovation Solution
A method of cutting multiple discrete sections from a sheet of uncured rubber and joining them to form a tread layer, which can be applied to a tire intermediate and cured, allowing for rapid creation and testing of different tread designs without the need for conventional extrusion equipment or extensive tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional extrusion equipment with tooling and dies is used to produce tire tread, then large production runs can be achieved, but significant scrap material is generated and expensive equipment is required
Solution Approach 1:
The tread is divided into multiple discrete sections that can be independently formed and then joined together. This segmentation allows for precise control of each section's dimensions and composition, minimizing material waste while enabling both small and large production runs without requiring expensive extrusion tooling.
2Manufacturing precision
If expensive tooling and dies are designed and manufactured for extrusion equipment, then consistent tread production is achieved, but significant time and resources are consumed before production can begin
Solution Approach 1:
Instead of investing in expensive, durable extrusion tooling and dies, the invention uses inexpensive, disposable tread sections that are cut to size and joined together. This eliminates the need for costly tooling manufacturing and setup time, allowing rapid production start while maintaining consistent tread quality through precise cutting and joining processes.
3Adaptability or versatility
If extrusion equipment is used for small production runs or testing, then tread can be produced, but the equipment inefficiency results in excessive material consumption and time requirements
Solution Approach 1:
The invention enables dynamic adaptation to different production requirements by cutting and joining varying numbers of tread sections as needed. This allows the same process to efficiently produce whether one tread or thousands of treads, providing flexibility for testing, small runs, or large production without the inefficiencies of fixed extrusion equipment.
4Productivity
If multiple pieces of costly extrusion equipment are required, then large scale tread production is achieved, but the equipment cost and complexity increase significantly
Solution Approach 1:
The invention replaces complex mechanical extrusion systems with a simpler process involving cutting and joining operations. This substitution eliminates the need for expensive extrusion equipment while maintaining high production capacity through efficient section fabrication and assembly processes.
Data Source
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AI summary
A method is provided for manufacturing tread for a tire without necessarily extruding the tread profile. The tread is created from multiple discrete parts that are cut from a sheet of uncured rubber material. The parts are joined together to create the tread, which can be applied to a tire immediate and cured to form a tire. Different treads formed from different rubber compositions may be created. The treads may also be created in varying shape and lengths with different rubber compositions used in different parts of the tread. One or more tread pieces can be applied to the same or different tire intermediates, which may be advantageous for simultaneous testing of different tread designs.