Tire Molding with Inflatable Bladder Insert for Sensor Integration
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Solution Overview
Problem
Current methods for integrating sensors into tires, such as using separate containers or solid core drums, are cumbersome, add weight, and limit the shape and location of the container, making it difficult to accommodate non-flat sensors and requiring multiple core sizes for different tire types and sizes.
Innovation Solution
A method of molding a tire using a flexible bladder with an insert that carries a cavity, where the bladder is inflated during the molding process to form a container on the tire's inner surface, allowing for the integration of sensors without additional processing steps or weight, and enabling various shapes and sizes of containers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate container is formed and attached to the tire after molding, then the container can be precisely formed, but it adds weight and requires additional processing steps
Solution Approach 1:
The container is merged with the tire structure by forming it as an integral part of the tire during the same molding process. The mold cavity is configured to form the container directly in the tire, eliminating the need for separate container formation and attachment steps, thus reducing production complexity while maintaining precision
Solution Approach 2:
The container cavity is prepared in advance within the mold structure before the tire molding begins. The mold cavity is pre-configured with the appropriate geometry and dimensions, allowing the container to be formed simultaneously with the tire without requiring subsequent processing steps
2Adaptability or versatility
If a solid core drum is used to form the container, then non-flat sensors can be accommodated, but variously sized solid cores are required for different tire types and sizes
Solution Approach 1:
The mold cavity serves multiple functions: it forms both the tire structure and the container simultaneously. This universal mold design eliminates the need for separate solid cores for different tire types, as the same mold can accommodate various container shapes and sizes through adjustable cavity configurations
Solution Approach 2:
The mold cavity is designed with adjustable or reconfigurable elements that can be modified to accommodate different container shapes and sizes. This dynamic adaptability allows the same mold to serve various tire types and sensor configurations without requiring different solid cores
3Device complexity
If a flap/container is molded into the tire during production, then the container is integrated into the tire, but the resulting flap is flat and cannot hold non-flat shaped electronic sensors
Solution Approach 1:
The mold cavity is designed with specific local geometry that imparts three-dimensional shape to the container portion of the tire. By configuring the cavity with appropriate curvature and depth, the container can accommodate non-flat sensors while remaining integrated into the tire structure during the molding process
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 allows for the efficient and lightweight integration of sensors within tires, enabling the use of non-flat sensors and reducing production complexity by forming the container directly during the tire molding process, without the need for separate components or solid cores.
Implementation Method 1
A flexible bladder with an insert is used. The bladder is inflated during the molding process to form a container on the tire's inner surface
Data Source
AI summary
A method of molding a tire that has a container (12) that includes the steps of placing an uncured tire into a mold, and providing a bladder (16) that has a flexible portion (18) and an insert (20) that has a cavity configured for molding the container into the tire. The bladder has a fluid therein and is inflated within the mold, and material of the uncured tire flows into the cavity of the insert (20). Sufficient heat and pressure is applied to the uncured tire to at least partially cure the tire when the uncured tire is in the mold. The material in the insert (20) forms the container (12) such that the container is integrally formed with other portions of the tire. The mold is opened to retrieve the tire.