Laser-Sintered Tire Mold Inserts with Wedge Anchoring
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Solution Overview
Problem
Conventional tyre moulding processes face challenges such as the single-use nature of friable dies, limitations in complexity of shapes due to EDM electrodes, and inability to produce small-dimensioned textures on aluminium insert elements, which are not resistant to curing environments.
Innovation Solution
A method using laser sintering to produce inserts made of stronger materials than aluminium, which are anchored in an aluminium body during casting, allowing for complex shapes and small-dimensioned textures, and a manufacturing process involving a die and counter-mould with wedges to ensure secure positioning and injection of aluminium without passage between the insert and moulding surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If friable dies are used for aluminium casting, then insert elements can be produced, but the dies allow only single use which is not ecologically favourable
Solution Approach 1:
The patent changes the material parameter of the die from friable material (plaster) to laser-sintered metal powder, transforming it from a single-use consumable to a reusable tooling component that can withstand multiple casting cycles
Solution Approach 2:
The patent employs composite material construction where a metal powder matrix is laser-sintered to create a durable die structure that integrates both the moulding surface and structural support in a single reusable component
2Ease of manufacture
If steel dies are used with EDM cavity sinking, then insert elements can be produced, but the complexity of shapes is limited by electrode constraints
Solution Approach 1:
The patent replaces the mechanical EDM electrode system with a laser-based additive manufacturing process, eliminating the geometric constraints of physical electrodes and enabling direct fabrication of complex three-dimensional moulding surfaces
Solution Approach 2:
The patent performs preliminary digital modeling and laser sintering of the die structure before casting, allowing complex geometries to be pre-formed with precise surface details that would be difficult or impossible to achieve with traditional electrode-based methods
3Ease of manufacture
If aluminium insert elements are used for moulding, then tyre profiles can be formed, but small-dimensioned textures cannot be produced as aluminium textures are not resistant to curing environments
Solution Approach 1:
The patent changes the material parameter of the insert elements from aluminium to laser-sintered metal powder with higher melting point and greater hardness, enabling the creation of durable small-dimensioned textures that can withstand curing temperatures and mechanical cleaning
Solution Approach 2:
The patent creates a composite structure where laser-sintered metal insert elements with embedded textures are integrated into the aluminium casting process, combining the formability of aluminium with the thermal and mechanical resistance of harder materials
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 method results in mould elements with improved resistance to curing and cleaning, increased hardness, and the ability to produce complex shapes and small-dimensioned textures, enhancing the durability and design capabilities of tyre moulds.
Implementation Method 1
placing at least one insert, produced by laser sintering, against a moulding surface of the die
Implementation Method 2
injecting aluminium into the moulding cavity of the manufacturing device
Data Source
AI summary
A method for manufacturing a mold element using a manufacturing device comprising a die and a counter-mold defining a molding cavity in the closed position, comprises: opening the manufacturing device; placing at least one insert 22, produced by laser sintering, against a molding surface of the die; mounting at least one wedge 28 on the die so as to bear against said insert in order to immobilize it relative to said molding surface; closing the manufacturing device, the counter-mold pressing onto said wedge in order to keep said insert pressed against said molding surface; injecting aluminium into the molding cavity of the manufacturing device; opening the manufacturing device; and extracting from the manufacturing device the mold element provided with a molding face formed by at least part of said insert and by the aluminum.