Terahertz Sensor Rubber Layer Thickness Detection
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Solution Overview
Problem
Existing methods for recycling rubber components, such as end-of-life tires, fail to effectively separate rubber from textile and metallic components, preventing de-vulcanization and limiting the reuse of recycled rubber due to energy-intensive processes and large footprints.
Innovation Solution
An apparatus using terahertz frequency electromagnetic signals to determine the thickness of the rubber layer on top of textile components, allowing precise removal of the rubber layer without touching the underlying textiles, combined with a rotor system for peeling and a de-vulcanization process to produce high-quality, reusable rubber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rubber components are shredded using prior art systems, then the rubber can be processed, but the output material becomes impure with textile and metallic components mixed in, preventing de-vulcanization
Solution Approach 1:
The invention segments the rubber component into distinct layers: the outer rubber layer is separated from the underlying textile components. The peeling device removes only the rubber layer while leaving the textile cords intact, achieving material separation at the source rather than attempting to separate shredded mixtures later.
Solution Approach 2:
The invention extracts the rubber layer from the composite structure by peeling it away from the textile components. This extraction occurs before any shredding or mixing, ensuring that the rubber is obtained in a pure state suitable for de-vulcanization, while the textile components remain as a separate fraction.
2Ease of manufacture
If multiple mill stations are used to soften and homogenize rubber, then the rubber can be reworked, but energy consumption and footprint increase significantly
Solution Approach 1:
The invention extracts the rubber layer in a clean, separated state directly from the tire structure. This eliminates the need for multiple processing stages (softening mills, homogenization mills) that would be required if starting from shredded mixed material, thereby reducing energy consumption and equipment footprint while maintaining rubber rework capability.
Solution Approach 2:
The rubber layer is peeled and separated in advance, before any de-vulcanization or reprocessing steps. This preliminary separation action simplifies subsequent processing by providing pure rubber input material, eliminating the need for multiple mechanical processing stages and reducing overall energy requirements.
3Ease of manufacture
If non-vulcanized rubber is processed through traditional reworking systems, then the rubber can be softened and homogenized, but vulcanized rubber cannot be effectively reworked
Solution Approach 1:
The invention extracts the rubber layer in its original vulcanized state, preserving its cross-linked structure. This extracted pure rubber can then be subjected to de-vulcanization processes to break the cross-links, enabling the reworking of vulcanized rubber which would otherwise be impossible through traditional mechanical means alone.
4Stability of the object's composition
If textile components are present in the rubber mixture, then the rubber component structure is maintained, but de-vulcanization cannot occur because impurities inhibit cross-link cracking
Solution Approach 1:
The invention segments the composite structure by peeling the rubber layer away from the textile cords. This physical segmentation removes the textile impurities that would otherwise inhibit de-vulcanization, while the rubber layer itself maintains its structural integrity during the peeling process for subsequent effective de-vulcanization.
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 separation of rubber from other materials, reducing energy consumption and footprint, producing high-quality, 100% reusable rubber suitable for new tire production, while improving eco-efficiency and reducing costs.
Implementation Method 1
transmit an electromagnetic signal with a terahertz frequency onto the rubber component, to receive an electromagnetic signal refracted or reflected at the rubber component
Implementation Method 2
transmit an electromagnetic signal with a terahertz frequency onto the rubber component, to receive an electromagnetic signal refracted or reflected at the rubber component
Data Source
Figure 1a~1b
Figure 2a
Figure 3
AI summary
The invention provides an apparatus (200) for removing rubber from a rubber component (8), preferably a rubber tire, wherein the rubber component comprises an outer rubber layer on top of textile components. The apparatus comprises a sensor (210) configured to transmit an electromagnetic signal (20) with a terahertz frequency onto the rubber component, to receive an electromagnetic signal (21) refracted or reflected at the rubber component, and to determine the thickness of the outer rubber layer on top of the textile components based on the received electromagnetic signal and a remover device (220) configured to remove the rubber from the outer rubber layer based on the determined thickness of the outer rubber layer on top of the textile components.