Tread Molding Lamella Sintering for Thin Sipe Geometry
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Solution Overview
Problem
Existing methods for producing molding elements with fine lamellas for tire treads are difficult and expensive due to the challenges of achieving precise dimensions using standard processes like milling.
Innovation Solution
A selective laser sintering method where the fine lamellas are sintered in multiple layers with the laser beam making only one passage in the same direction at each layer, allowing for the production of fine lamellas with a thickness less than 0.2mm and complex shapes without round-trip passages, and ribs are sintered in multiple layers with varying paths to optimize production time and reduce weakness zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard processes like milling are used to produce fine lamellas, then manufacturing precision can be achieved, but the production becomes difficult and expensive
Solution Approach 1:
The patent replaces mechanical milling processes with selective laser sintering technology. The laser beam selectively sinters metal powder to create fine lamellas with thickness less than 0.2mm, eliminating the need for complex mechanical machining while achieving the required precision and reducing production cost.
Solution Approach 2:
The patent changes the manufacturing approach from mechanical removal (milling) to thermal addition (laser sintering). By controlling laser parameters such as power, speed, and focal position, the process achieves precise dimensional control of fine lamellas with thickness under 0.2mm, resolving the contradiction between precision and ease of manufacture.
2Reliability
If the laser beam makes multiple round-trip passages to sinter powder, then sintering completeness is improved, but production time increases
Solution Approach 1:
The patent transitions from bidirectional round-trip laser passages to unidirectional single-pass sintering by optimizing the laser beam parameters and powder bed preparation. The laser beam moves in one direction along the fine lamella length, and through precise control of laser power and focus, achieves complete sintering without requiring return passages, thus halving the production time while maintaining sintering quality.
Solution Approach 2:
The patent performs preliminary preparation of the metal powder layer before laser sintering, ensuring optimal powder distribution and density. This preliminary action allows the laser beam to sinter the powder completely in a single pass, eliminating the need for multiple round-trip passages and significantly reducing production time while maintaining reliability.
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 enables the cost-effective production of fine lamellas and ribs with improved rigidity and density, enhancing the tire's grip and braking performance on icy roads by maintaining low thickness and height while optimizing production efficiency.
Implementation Method 1
a first layer of metallic powder is spread on a plate. All or some of the particles of this first layer of powder are then agglomerated by the beam of a laser according to the shape of the object that is to be obtained
Implementation Method 2
The beam of the laser makes a plurality of round-trip passages to sinter the powder
Data Source
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AI summary
The invention relates to a selective laser sintering method of manufacturing a tread molding element (1), said tread molding element (1) comprising at least a fine lamella (20) adapted to mold a shallow sipe in a tread tyre, the fine lamella having a length (L2). The fine lamella is sintered in a plurality of portions (p2) at different layers (N), in each layer (N) the laser beam sinters the portion (p2) of the fine lamella in only one passage in the length (L2) of the fine lamella (20) without round-trip passage of the laser beam, the direction (D1) of this passage being the same at the different layers (N) for building the different portions (p2) of the fine lamella (20). The thickness (w) of the fine lamella is smaller than 0,2 mm, and the height (h) of the fine lamella 20 is smaller than or equal to 2 mm.