Solid Rubber Tyre Two-Stage Vulcanization
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Solution Overview
Problem
Existing methods for producing solid rubber tires result in uncontrollable material flow during vulcanization, leading to inconsistent material distribution and performance fluctuations, with conventional construction methods constraining the optimization of rolling resistance and tread performance.
Innovation Solution
A two-stage assembly process where a vulcanized base body is first created and then completed with a tread part and lateral tire flanks in a second stage, allowing for precise material distribution and optimal performance through application-specific rubber mixtures, with the option to use recycled materials and pre-vulcanized base bodies for efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a one-stage construction process is used where all rubber mixtures are wound and vulcanized together, then the production process is simple and fast, but the material distribution becomes uncontrollable and inconsistent
Solution Approach 1:
The patent divides the construction process into two separate stages: first constructing and vulcanizing the base body, then adding the tread part and lateral tire flanks in a second stage. This segmentation allows each stage to be optimized independently, ensuring consistent material distribution in the base body while enabling precise placement of tread materials, thereby resolving the contradiction between production speed and material distribution consistency.
Solution Approach 2:
The base body is constructed and vulcanized in advance before the tread part is added. This preliminary action ensures that the base body achieves stable and consistent material distribution and structural integrity before the final assembly, allowing the tread part to be precisely positioned without affecting the base body's material distribution.
2Ease of manufacture
If conventional construction methods are used with massive flow processes during vulcanization, then the production process is straightforward, but the material distribution does not correspond to the desired specification and tire properties fluctuate
Solution Approach 1:
By separating the construction into two stages with intermediate vulcanization, the patent eliminates the massive uncontrollable flow processes that occur in one-stage construction. The first stage vulcanizes the base body with controlled material distribution, and the second stage adds the tread part, ensuring consistent tire properties and reliable performance.
Solution Approach 2:
The base body is vulcanized in advance to establish stable material distribution and structural properties before the tread part is added. This preliminary vulcanization prevents material mixing and flow issues, ensuring that the final tire meets desired specifications with consistent performance.
3Reliability
If application-specific rubber mixtures are used for the tread part, then tread performance is optimized, but the constriction behavior of certain rubber mixtures occurs with conventional construction methods
Solution Approach 1:
The two-stage construction process allows application-specific rubber mixtures to be used for the tread part without suffering from constriction behavior. The base body is fully vulcanized first, creating a stable foundation that prevents unwanted material flow and constriction when the tread mixture is added and vulcanized in the second stage, thereby maintaining both optimized tread performance and precise material distribution.
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 consistent component boundaries and material distribution, optimizing tread performance and reducing energy requirements by allowing for tailored rubber mixtures and the use of recycled materials, resulting in high-quality solid rubber tires with improved rolling resistance and durability.
Implementation Method 1
The green tire is then vulcanized in a heating mold... the base body being built up and vulcanized in the first stage... and then the tire is vulcanized again
Data Source
Figure 1~3
AI summary
Method for producing a solid rubber tyre for a mobile working machine, comprising a base body (1) made of a radially inner base part (2) which comes in contact with a rim and a radially outer elastic part (3) and comprising a tread element (5) and two lateral tyre flanks (6), which laterally cover at least the elastic part (3), wherein the base part (2) and the elastic part (3) are each constructed by a multi-layer winding of a calendered rubber mixture, and wherein the tread element (5) and the two lateral tyre flanks (6) are likewise formed from rubber mixtures. The solid rubber tyre is produced in a two-stage construction method, wherein in the first stage the base body (1) is constructed and vulcanised, and wherein in the second stage the vulcanised base body (1) is completed with the tread element (5) and the lateral tyre flanks (6) and then the tyre is vulcanised again.