Rubber reinforcing material with reduced weight, method of preparing the same, and tire comprising the same
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Solution Overview
Problem
Existing tire manufacturing processes increase tire weight and cost due to rolling processes, making it difficult to achieve thin, lightweight rubber reinforcing materials with excellent durability.
Innovation Solution
A rubber reinforcing material comprising a fiber base woven with warp and weft yarns, an adhesive layer, and a rubber compound layer, where the warp yarns have a fineness of 420 to 800 denier and a density of 55 to 65/inch, and the weft yarns have a dry heat shrinkage of -1.0% to +3.0%, allowing for direct bonding without rolling, resulting in a thin, durable material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rolling process is used to bond tire cord and rubber, then bonding strength is improved, but tire weight increases and manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the rolling process from the tire manufacturing sequence, allowing tire cord and rubber to bond directly through their inherent adhesion properties. This removal of the intermediate rolling step reduces added weight and manufacturing cost while maintaining bonding strength through direct contact between materials.
Solution Approach 2:
The patent introduces a specific fiber base structure with controlled porosity and surface characteristics that acts as an intermediary between tire cord and rubber, enabling direct bonding without rolling. The fiber base's physical properties facilitate adhesive interaction, allowing the materials to bond effectively through their own properties rather than mechanical rolling.
2Length of moving object
If solid rubber is rolled to form thin film (200 μm or less), then rubber layer thickness is reduced, but manufacturing difficulty increases and product quality deteriorates
Solution Approach 1:
The patent changes the physical state of rubber from solid to liquid form, allowing it to be applied as a coating solution that can uniformly form thin films at controlled thicknesses. This parameter change from solid to liquid enables precise thickness control and uniform distribution without the manufacturing difficulties associated with rolling solid rubber into thin films.
Solution Approach 2:
The patent replaces the mechanical rolling process with a chemical/coating application process. Instead of mechanically rolling solid rubber, the rubber is applied as a liquid coating solution that forms the desired thin film through evaporation and curing, substituting mechanical action with a chemical-physical process.
3Strength
If rolling process is applied for tire cord bonding, then bonding is achieved, but manufacturing cost increases
Solution Approach 1:
The patent extracts and eliminates the rolling process from the manufacturing sequence, allowing direct bonding of tire cord and rubber through their inherent adhesion properties. This removal simplifies the manufacturing process, reduces equipment requirements, and lowers manufacturing cost while maintaining bonding strength.
Solution Approach 2:
The patent enables the tire cord and rubber to bond through their own inherent properties without requiring external rolling assistance. The fiber base structure and rubber coating solution are designed to self-bond through adhesion, eliminating the need for costly rolling equipment and processes.
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 material reduces tire weight and manufacturing costs, improves fuel efficiency, and decreases rolling resistance, enhancing the performance of automobiles.
Implementation Method 1
applying a rubber coating solution on the adhesive layer and heat treating to form a rubber compound layer on the adhesive layer
Implementation Method 2
heat treating to form a rubber compound layer on the adhesive layer
Implementation Method 3
the weft yarn has dry heat shrinkage of −1.0% to +3.0% according to the standard test method of ASTM D 885 (177° C., 2 minutes, load of 0.05 g/de)
Data Source
AI summary
This invention relates to rubber reinforcing material with reduced weight, a method for preparing the same, and a tire including the same. According to this invention, there is provided a rubber reinforcing material that has a thin thickness and light weight, and yet has excellent durability. The reinforcing material not only reduces the weight of a tire, but also enables realization of improved rolling resistance.