Segmented Pressure-Bond Rollers for Uniform Tire Carcass Ply Adhesion
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Solution Overview
Problem
In tire building, the existing methods for pressure-bonding carcass ply sheets onto rubber laminating members with recessed and projected shapes result in uneven pressure distribution, leading to air gaps, deformation, and reduced quality due to excessive force concentration on projected portions and insufficient bonding at recessed areas.
Innovation Solution
A method using a stitcher apparatus with pressure-bond rollers arranged in a circular pattern with axis centers tangential to a concentric circle, allowing progressive displacement inward to ensure uniform pressure bonding over the entire periphery without excessive force, preventing air gaps and deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a pressure-bond roller of length substantially in correspondence with the width of the building drum is used to pressure-bond the carcass ply sheet, then the entire periphery can be covered, but excessive press force concentrates on projected portions causing deformation and insufficient bonding at recessed portions creating air gaps
Solution Approach 1:
The single pressure-bond roller is divided into multiple segmented rollers (first, second, third, and fourth pressure-bond rollers) arranged in parallel. Each roller applies pressure to a specific zone of the carcass ply sheet, distributing the press force uniformly across the entire width and preventing both air gaps and deformation.
Solution Approach 2:
Different pressure-bond rollers are positioned to apply pressure to different local zones of the carcass ply sheet corresponding to the recessed and projected portions of the rubber laminating member. This ensures that each local area receives appropriate pressure distribution, with recessed portions receiving sufficient pressure without over-compressing projected portions.
2Strength
If press force is intensified to increase adhering force, then bonding strength improves, but deformation and warp are produced at the carcass cord
Solution Approach 1:
The total press force required for strong bonding is divided and distributed across multiple segmented pressure-bond rollers. Each roller applies a portion of the total force, achieving the required adhering strength without concentrating excessive force on any single point that would cause deformation of the carcass cord.
3Productivity
If building cycle time is reduced by using moving building drum, then productivity increases, but quality control becomes more difficult
Solution Approach 1:
The multiple pressure-bond rollers are pre-positioned in fixed relationships to each other before the pressure-bonding operation begins. This preliminary arrangement ensures that as the building drum moves through the pressure-bonding zone, the segmented rollers maintain proper spacing and alignment, preserving pressure bonding uniformity despite the moving drum operation.
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
This approach ensures firm and uniform pressure bonding along recessed and projected shapes, preventing air gaps and deformations, thus enhancing tire quality and reducing building cycle time.
Implementation Method 1
the carcass ply sheet is pressed to be pressure-bonded simultaneously over an entire periphery by the pressure-bond rollers
Data Source
AI summary
The invention enables to pressure-bond a carcass ply sheet pasted onto a rubber laminating member wound around a periphery of a building drum firmly along a recessed and projected shape of the rubber laminating member without producing a deformation or a warp of a carcass cord, by using a stitcher apparatus constituted by arranging a plurality of pressure-bond rollers having axis centers in a tangential direction of a concentric circle having a diameter larger than that of a building drum in a peripheral direction by a plurality of rows and by a constant pitch by being respectively supported to be able to progressively displace to an inner side in a diameter direction, while moving the building drum in an axial direction relative to the pressure-bond rollers on an inner side of a circular arrangement of the pressure-bond rollers, a carcass ply sheet is pressed by a predetermined pressure to pressure-bond over an entire periphery and simultaneously by the respective pressure-bond rollers progressively displaced to the inner side in the diameter direction.