Tire Tread String Embedding via Furrow Insertion
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Solution Overview
Problem
The existing coextrusion technique for manufacturing vehicle tire treads with embedded strings often results in manufacturing defects, leading to waste due to the simultaneous extrusion of strings and tread, which complicates the process and makes material recovery difficult.
Innovation Solution
A process where rubber strips are extruded, furrows are formed in the strips, pre-manufactured strings are inserted into these furrows, and the furrows are reclosed over the strings using contiguous rubber material, eliminating the need for stabilization stages and reducing waste by allowing separate production of strings and their embedding in the rubber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coextrusion technique is used to produce treads with embedded strings simultaneously, then the strings are properly embedded in the rubber, but manufacturing defects occur frequently and material waste increases
Solution Approach 1:
The manufacturing process is divided into separate stages: first producing the rubber strip with furrows, then separately inserting pre-manufactured strings into the furrows, and finally reclosing the furrows. This segmentation allows each component to be optimized independently and eliminates the need for simultaneous coextrusion, reducing manufacturing defects and material waste while maintaining proper string embedding.
Solution Approach 2:
The strings are manufactured in advance as pre-formed components and stored in coils before being inserted into the furrows. The furrows are also formed in advance in the rubber strip. This preliminary preparation of components allows for quality control and adjustment before final assembly, reducing defects and enabling easier recovery of materials if defects occur.
2Productivity
If coextrusion technique is used to produce treads with embedded strings simultaneously, then the strings and tread are produced together, but the process complexity increases and stabilization stages are required
Solution Approach 1:
The complex coextrusion process is segmented into simpler, sequential operations: extruding the rubber strip, forming furrows, inserting strings from coils, and reclosing furrows. Each operation uses simpler, more reliable equipment that can be independently optimized and maintained, reducing overall process complexity while maintaining productivity.
Solution Approach 2:
Both the rubber strip and strings are prepared in advance as separate components. The rubber strip is extruded and furrows are formed before string insertion, eliminating the need for simultaneous coordination of multiple extrusion processes. This preliminary preparation removes the need for stabilization stages and simplifies the manufacturing process.
3Loss of substance
If strings are produced separately in advance and inserted into furrows, then material waste is reduced, but proper embedding of strings in rubber must be ensured
Solution Approach 1:
The string is inserted into the furrow and then the furrow material is reclosed over the string, nesting the string within the rubber matrix. This nesting approach ensures proper embedding and bonding of the string in the rubber while allowing for separate production of components, reducing material waste and improving manufacturing precision.
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 reduces manufacturing defects and waste by allowing for the separate production and proper embedding of strings within the rubber, improving the efficiency and accuracy of the tread manufacturing process.
Implementation Method 1
a strip made of rubber is extruded
Data Source
AI summary
In the process for producing a tread (4) for a vehicle tire: a tread strip made of rubber (4) is extruded; at least one furrow (44) is formed in the tread strip, the tread strip exhibiting material that is contiguous with the furrow; at least one string (8) is supplied from a coil; the string is inserted into the one furrow or each furrow; and the furrow is reclosed over the string using material of the tread strip that is contiguous with the furrow.