Self-Sealing Tyre Coating Process With Automated Spraying and Cooling
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Solution Overview
Problem
Current manufacturing processes for self-sealing tyres are not highly automated, rely heavily on operator experience, and require long cooling times, making them inefficient and difficult to scale up.
Innovation Solution
A process involving a cleaning step with alcohols or graphitic solutions, a spraying step with heated high molecular organic material, and a forced-cooling step to form a self-sealing layer on the tyre's inner liner, using automated systems to ensure precision and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated spraying system is used, then manufacturing precision and automation extent are improved, but device complexity increases
Solution Approach 1:
The patent replaces manual mechanical spraying operations with an automated spraying system that uses computer-controlled mechanisms. The system includes automated positioning devices, controlled spraying nozzles, and integrated control units that coordinate the spraying process, eliminating the need for operator intervention and ensuring consistent spraying quality through precise mechanical control.
Solution Approach 2:
The automated spraying system allows for precise control and adjustment of spraying parameters such as spray rate, nozzle distance, angle, and material temperature. These parameters can be programmatically changed and optimized for different tyre types and coating requirements, enabling high precision spraying while maintaining system adaptability through software control rather than physical reconfiguration.
2Productivity
If forced-cooling step is implemented, then cooling time is reduced and productivity is improved, but energy consumption increases
Solution Approach 1:
The forced-cooling system uses periodic cycles of high-intensity cooling followed by shorter intervals, rather than continuous maximum cooling. The system activates cooling mechanisms at specific stages of the manufacturing process when the coating is most vulnerable, and reduces or pauses cooling when the material is stable, optimizing the balance between cooling effectiveness and energy consumption.
Solution Approach 2:
The forced-cooling step utilizes phase transition principles by controlling the temperature reduction rate to manage the thermal state of the coating material. The system transitions the coating from a high-temperature applied state through controlled cooling phases to a stable low-temperature state, using thermal management strategies that minimize energy waste while achieving rapid cooling.
3Reliability
If thickened and reinforced tyre walls are used, then reliability is improved, but riding comfort deteriorates
Solution Approach 1:
Instead of uniformly thickening the entire tyre wall, the patent applies the self-sealing coating selectively to specific areas where puncture protection is most needed, such as the tread and shoulder regions. The coating is applied in varying thicknesses based on the local stress and puncture risk, providing enhanced protection at critical locations while maintaining the original tyre wall thickness and comfort characteristics in other areas.
Solution Approach 2:
The patent creates a composite structure by combining the original tyre materials with the self-sealing coating layer. The coating acts as a functional composite material that provides puncture resistance and self-sealing properties without requiring structural changes to the base tyre. This composite approach allows the tyre to maintain its original comfort characteristics while gaining enhanced protective functions.
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 process achieves high-quality, self-sealing tyres with improved riding comfort and safety by automating operations, reducing manufacturing time, and ensuring consistent performance across large-scale production.
Implementation Method 1
a spraying step for spraying the heated high molecular organic material on the inner liner of the tyre to be treated
Implementation Method 2
a forced-cooling step for forcibly cooling the tyre to be treated that has been sprayed with the high molecular organic material
Implementation Method 3
an air-drying procedure, in which the alcohols solution or a graphitic solution on the tyre to be treated is evaporated with air-drying gases
Data Source
AI summary
The present disclosure relates to a process and a system for manufacturing an HSST tyre, as well as the HSST tyre manufactured by the same. The process for manufacturing an HSST tyre includes a cleaning step, a spraying step, and a forced-cooling step. The cleaning step includes an air-drying procedure for evaporating the isopropanol solution on the tyre to be treated with air-drying gases. The forced-cooling step is configured to forcibly cool the tyre to be treated that has been sprayed with the high molecular organic material. By means of accurate design for each step and procedure, the relying on operator's experience is eliminated and thus the performance stability of the HSST tyre is guaranteed. By means of the air-cooling procedure and the forced-cooling step, the time taken to manufacture an HSST tyre is substantially shortened, making it possible to produce the HSST tyre in a large scale.