Tire Core Cooling Station Immersion Method
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Solution Overview
Problem
Existing tire manufacturing processes face inefficiencies in cooling the core after vulcanization, leading to prolonged cycle times due to inadequate cooling methods, such as air circulation or liquid nitrogen, which do not effectively reduce the core's temperature quickly enough for subsequent assembly phases.
Innovation Solution
The core is immersed in a tank of refrigerated water while rotating, with controlled parameters like water temperature, immersion depth, and speed to rapidly lower the surface temperature to a range compatible with rubber deposition, using a cooling station that ensures efficient heat transfer and minimal mechanical deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If air circulation is used to cool the core, then the cooling process is simple to implement, but the cooling speed is too slow to optimize cycle times
Solution Approach 1:
The patent applies hydraulic cooling by circulating chilled water through channels formed in the core itself. This internal water circulation system enables rapid heat removal from the core, achieving the required cooling speed while maintaining structural integrity and avoiding the slowness of external air circulation methods.
2Productivity
If liquid nitrogen is used for cooling, then rapid cooling is achieved, but the method is not suitable for tire manufacturing cores
Solution Approach 1:
The patent changes the cooling parameter from extreme cryogenic temperatures (liquid nitrogen) to moderate chilled water temperatures. This parameter adjustment makes the cooling method suitable for tire manufacturing cores while still achieving rapid cooling, as the chilled water temperature can be optimized for the specific thermal requirements of the core and tire assembly process.
Solution Approach 2:
The patent replaces gas-phase liquid nitrogen cooling with liquid-phase chilled water circulation. This hydraulic approach is better suited for the tire manufacturing environment, providing controlled, uniform cooling that is compatible with the materials and processes used in tire production, unlike liquid nitrogen which introduces condensation and material compatibility issues.
3Productivity
If the core is cooled rapidly, then cycle time is reduced, but thermal shock may occur causing mechanical deformation
Solution Approach 1:
The patent implements localized cooling by forming cooling channels directly within the core structure, allowing different regions of the core to be cooled at different rates. This enables rapid overall cooling while controlling thermal gradients to prevent thermal shock and mechanical deformation, as each section of the core can be cooled according to its specific thermal mass and geometry.
Solution Approach 2:
The hydraulic cooling system uses circulated chilled water that can be temperature-controlled and flow-rate-adjusted. This provides gradual, controlled heat removal that reduces thermal shock compared to sudden extreme cooling, while still achieving rapid cooling overall. The water circulation system allows for uniform heat distribution and controlled thermal gradients throughout the core.
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 method effectively reduces the core's temperature from 70° C to 100° C in less than 5 minutes, optimizing cycle times by ensuring a stable surface temperature for assembly, while avoiding thermal shocks and mechanical alterations.
Implementation Method 1
The thin film of water deposited during immersion evaporates when the surface of the corresponding core passes to the open air, which has the effect of accelerating heat transfer.
Implementation Method 2
The thin film of water deposited during immersion evaporates when the surface of the corresponding core passes to the open air, which has the effect of accelerating heat transfer.
Data Source
Figure 1
Figure 2
AI summary
The station has a frame (232) supporting a maintaining unit (231) that clutches and rotates a core (N) around a rotational axis. A trough (233) contains chilled water in which a part of the surface of the core is partially immersed. The unit (231) tilts around a horizontal axis so as to make the rotational axis of the core to pass from a vertical position towards a horizontal position and reciprocally. An independent claim is also included for a method for cooling a core.