Segmented Tire Die Inserts for Cost-Effective Texture Production
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Solution Overview
Problem
Current methods for manufacturing tire molds are costly and inflexible, requiring significant changes when architectural or dimensional changes occur in the final product, and are limited by the high expense of specific base materials.
Innovation Solution
A die representing a tire tread pattern with separate, precisely textured inserts made using 3D printing, laser machining, or selective melting, which can be attached to a die body, allowing for high-precision, cost-effective production of molds with complex textures, enabling multiple mold variants from a single die.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a one-piece element is manufactured by laser sintering, then the part can be easily modeled by computer and manufactured, but the design and manufacture must be reviewed as soon as architectural or dimensional changes occur, and large parts are relatively expensive to produce
Solution Approach 1:
The die is divided into a die body and separate inserts that can be independently manufactured and then assembled. This segmentation allows each component to be optimized separately and enables easy replacement or modification of inserts without redesigning the entire die, thus resolving the contradiction between ease of manufacture and adaptability to design changes.
2Ease of manufacture
If specific base materials are used for laser sintering, then the manufacturing process is feasible, but large parts are relatively expensive to produce
Solution Approach 1:
By segmenting the die into a body and separate inserts, the inserts can be manufactured using cost-effective methods such as 3D printing, laser machining, or electro-erosion rather than requiring expensive laser sintering for the entire component. This reduces material costs while maintaining manufacturing feasibility.
Solution Approach 2:
The inserts can be manufactured as separate, potentially replaceable components using more economical manufacturing methods. If wear or damage occurs, only the inserts need to be replaced rather than the entire die, reducing long-term production costs.
3Manufacturing precision
If complex textures are required on difficult-to-access surfaces, then high precision is needed, but conventional manufacturing methods become increasingly expensive
Solution Approach 1:
Complex textured surfaces are created on separate inserts rather than the entire die. This allows specialized manufacturing processes to be applied only where needed, and the inserts can be manufactured using appropriate high-precision methods without requiring the entire die to be manufactured with the same level of complexity and cost.
Solution Approach 2:
The inserts act as intermediary components that carry the complex textures. These inserts can be manufactured using advanced techniques like 3D printing or laser machining that are capable of creating complex geometries, and then assembled to the die body, thereby achieving high precision textures without requiring the entire die to be manufactured with equal complexity.
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 enables the production of high-precision tire molds with complex textures at lower costs, allowing for easy adaptation to design changes and the creation of multiple mold variants, while reducing production expenses and ensuring consistent quality across all surfaces.
Implementation Method 1
The separate inserts are provided with separate textures and the inserts are manufactured separately, under conditions allowing the shaping of the textures, then attached to the body of the die and in that the fixing of the inserts is by screwing
Implementation Method 2
The textures of the inserts are made by 3D printing or laser machining, or using punches, or by selective melting of metal powder, or by electro-erosion
Implementation Method 3
The textures of the inserts are made by 3D printing or laser machining, or using punches, or by selective melting of metal powder, or by electro-erosion
Implementation Method 4
The textures of the inserts are made by 3D printing or laser machining, or using punches, or by selective melting of metal powder, or by electro-erosion
Implementation Method 5
The textures of the inserts are made by 3D printing or laser machining, or using punches, or by selective melting of metal powder, or by electro-erosion
Data Source
Figure 1~4
Figure 5a~5b
Figure 6~11
AI summary
The invention relates to a die (1) representing a tread pattern model for a tyre to be moulded, said die being formed by a die body (2) and at least one insert (10) attached to the body of the die and covering at least one of the surfaces of the furrows (4) of the body (2), said insert comprising at least one substantially flat surface provided with textures.