Rubber-Reinforced Tire Composite With Thin Airtight Inner Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing rubber-reinforced composites face challenges in achieving high airtightness and mechanical strength with minimal material thickness and homogeneity, particularly in components like pneumatic tires and air springs, while maintaining low heat generation and reducing inhomogeneities.
Innovation Solution
A rubber-strength carrier composite is designed with a gas-tight inner layer made of a rubber compound and a carcass layer with strength carriers encased by a carcass rubber coating layer, utilizing calendering to form a thin inner layer and reducing splices, with optional asymmetric or symmetric arrangements of the carcass rubber lining layer to enhance force transmission and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the inner layer is made thinner to reduce material thickness and mass, then heat generation decreases and airtightness improves, but manufacturing difficulty increases and reject rate increases
Solution Approach 1:
The carcass rubber layer is prepared in advance with the inner layer already positioned and secured before the final assembly process. This preliminary positioning ensures that when the inner layer is calendered, it is already correctly aligned, preventing manufacturing defects and reducing reject rates despite the thinness of the inner layer.
Solution Approach 2:
The carcass rubber layer serves as an intermediary medium that facilitates the manufacturing process. By calendering the inner layer around and encasing the carcass rubber layer, the process uses the carcass layer as a form or mediator to achieve uniform thinness without direct manipulation of the fragile thin inner layer, thereby reducing manufacturing difficulty and rejects.
2Temperature
If the inner layer is made thinner to reduce material thickness, then heat generation during deformation decreases, but airtightness may be compromised
Solution Approach 1:
The invention uses a composite structure combining the thin inner layer with the carcass rubber layer. The inner layer provides the airtight barrier function, while the carcass rubber layer provides structural support and reinforcement. This composite approach allows the inner layer to be extremely thin (reducing heat generation) while the carcass layer ensures airtightness is maintained through its encasement and structural integrity.
Solution Approach 2:
The inner layer is calendered around and encases the carcass rubber layer, creating a nested structure. This nesting arrangement allows the thin inner layer to conform precisely to the carcass layer's shape, ensuring complete enclosure and maintaining airtightness even at minimal thickness, while the carcass layer provides the structural backbone.
3Stability of the object's composition
If the number of splices is reduced to improve homogeneity, then inhomogeneities decrease, but manufacturing complexity may increase
Solution Approach 1:
The carcass rubber layer is designed as a continuous structure that extends along the entire length of the pneumatic component. This continuity eliminates the need for multiple splices or joints in the carcass layer, ensuring homogeneous properties throughout the component. The continuous carcass layer maintains structural integrity and uniform performance without requiring complex splicing operations.
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 composite achieves high airtightness and mechanical strength with minimal thickness, reduced heat generation, and improved homogeneity, enabling efficient production with low material waste and enhanced durability.
Implementation Method 1
This problem is solved by calendering the inner layer around and encasing a carcass rubber layer during its production or shaping.
Implementation Method 2
The carcass rubber liner is typically a sulfur-curable rubber compound. Its high dynamic and mechanical resistance, as well as its low tendency to crack formation and propagation, contribute significantly to the durability of the rubber-support composite.
Data Source
Figure 1~2
AI summary
The invention relates to a rubber-strength carrier composite (1), in particular a pneumatic tire component, with a gas-tight inner layer (2) made of a rubber compound and a carcass layer (3) with strength carriers (4), wherein the strength carriers (4) are encased by a carcass rubber coating layer (5).