3D-Printed Tire Segment Model with Integrated Polymer Blades
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Solution Overview
Problem
Current tire mold manufacturing processes are time-consuming and costly, with limitations in achieving precise geometric specifications and complex three-dimensional structures, and existing 3D printing methods for metal molds are expensive and lack reproducibility.
Innovation Solution
A 3D-printed tire segment model with polymer blades extending from ribs and tread blocks, using stereolithography for high accuracy and efficiency, which integrates blades and complex patterns, and a method involving a negative cast with metal blades for forming a tire mold segment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional mold manufacturing processes are used, then geometric specifications and tolerance accuracy are achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent replaces traditional mechanical mold manufacturing processes (milling, turning, manual blade attachment) with 3D printing technology. The 3D-printed tire segment model is created additively with integrated blades, eliminating the need for separate blade attachment steps and reducing manufacturing time while maintaining geometric precision through digital modeling and controlled deposition processes.
Solution Approach 2:
The patent merges the blade structure directly into the tire segment model during the 3D printing process. The blades are printed as integral parts of the tread blocks and ribs, combining what were previously separate manufacturing steps (creating the segment model and then attaching blades) into a single additive manufacturing process, thereby reducing time and labor.
2Productivity
If metal powder direct printing is used for mold manufacturing, then manufacturing time is reduced, but cost increases and fine structure reproducibility decreases
Solution Approach 1:
The patent changes the material parameter from metal powder to polymer material for the 3D printing process. This parameter change enables better fine structure reproducibility through the layer-by-layer deposition mechanism of stereolithography and material extrusion, while maintaining reduced manufacturing time compared to traditional methods. The polymer material allows for precise control of blade geometry and tread patterns.
3Extent of automation
If automated milling machines are used for mold manufacturing, then some process steps are automated, but complex three-dimensional tire tread designs are limited
Solution Approach 1:
The patent replaces the subtractive manufacturing approach of automated milling machines with additive manufacturing (3D printing). This substitution allows for the creation of complex three-dimensional tire tread designs including integrated blades, sipes, and varying groove patterns that cannot be achieved with conventional milling tools, thereby significantly increasing design versatility while maintaining automation.
4Manufacturing precision
If multi-step processes are used to create tire segment models with blades, then manufacturing precision is maintained, but manufacturing complexity and time increase
Solution Approach 1:
The patent combines the creation of the tire segment model and the blades into a single 3D printing process. The blades are printed as integral parts of the tread blocks and ribs, eliminating the need for separate blade attachment steps. This merging maintains blade positioning accuracy through digital modeling while significantly reducing manufacturing process complexity.
Solution Approach 2:
The patent uses digital 3D modeling to create a precise virtual copy of the tire segment with integrated blades before physical manufacturing. The digital model contains all geometric information for the tread pattern, ribs, and blades, which is then directly translated into the physical 3D-printed object, ensuring high positioning accuracy without complex manual procedures.
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 reduces manufacturing time and cost by directly integrating blades and complex patterns in the tire segment model, enabling more efficient and accurate tire mold production with improved mechanical stability and design flexibility.
Implementation Method 1
stereolithography for high accuracy and efficiency
Data Source
AI summary
The present invention is directed to a 3D-printed tire segment model having a tread portion comprising a plurality of grooves, ribs and/or tread blocks, and a plurality of blades extending out of the ribs and/or tread blocks, wherein the tire segment model is made of a 3D-printed polymer. Moreover, the present invention is drawn to a method of making a tire mold segment, including the step of 3D-printing the above tire segment model with a polymer.