Rubber Coating of Twisted Wire Cord Without Strand Unraveling
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Solution Overview
Problem
Existing methods for coating twisted wire cords with unvulcanized rubber often result in unraveling, leading to defects such as exposed wire strands or eccentric deformation, which affect the quality of rubber products.
Innovation Solution
A method and device that continuously coat unvulcanized rubber on a twisted wire cord by imparting additional tension to the wire cord before coating, using a tension imparting unit positioned upstream from the coating unit, ensuring the wire strands remain tightly bundled and preventing unraveling during the coating process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If unvulcanized rubber is coated on a twisted wire cord during manufacturing, then the wire cord is protected and ready for rubber product production, but the pressure from coating causes the twisted wire cord to unravel and deform
Solution Approach 1:
The patent applies preliminary anti-action by introducing a tensioning device upstream of the coating unit that applies tension to the twisted wire cord before coating. This pre-applied tension counteracts the unraveling force generated during rubber coating, preventing the wire cord from loosening or deforming under coating pressure. The tensioning force is applied in advance to maintain structural integrity throughout the coating process.
Solution Approach 2:
The patent implements preliminary action by tightening the twisted wire cord with a tensioning device before the unvulcanized rubber coating process begins. This preliminary tightening ensures the wire cord maintains its twisted structure during subsequent coating operations, preventing defects such as exposed wire strands or eccentric deformation that would otherwise occur under coating pressure.
2Stability of the object's composition
If resin is used to coat and cure the twisted wire cord instead of unvulcanized rubber, then the wire cord can be prevented from unraveling through re-twisting, but unvulcanized rubber cannot be cured quickly like molten resins and excessive curing reduces adhesive strength
Solution Approach 1:
The patent applies preliminary anti-action by using a tensioning device to prevent unraveling during the coating process, eliminating the need for subsequent re-twisting operations. This approach works effectively with unvulcanized rubber coating, allowing the coating to be applied without excessive curing that would reduce adhesive strength, thereby avoiding the time loss associated with multiple processing steps.
3Stability of the object's composition
If the twisted wire cord is re-twisted after coating with resin or unvulcanized rubber, then some unraveling may be corrected, but defects such as exposed wire strands or eccentric deformation cannot be sufficiently prevented
Solution Approach 1:
The patent implements preliminary action by applying tension to tighten the twisted wire cord before the coating process begins. This preliminary tightening prevents unraveling during coating, ensuring that the coating is applied uniformly without defects such as exposed wire strands or eccentric deformation. By preventing defects at the source rather than attempting to correct them after coating, manufacturing precision is significantly improved.
Solution Approach 2:
The patent applies preliminary anti-action by using a tensioning device upstream of the coating unit to counteract the forces that would cause unraveling or deformation during coating. This pre-applied tension maintains the wire cord's structural integrity throughout the coating process, preventing defects before they occur and eliminating the need for post-coating re-twisting operations.
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 stable coating of the twisted wire cord with unvulcanized rubber, preventing defects and ensuring a high-quality rubber product by maintaining the twist and bundling of the wire strands even under the pressure of the coating rubber.
Implementation Method 1
additional tension is imparted to the twisted wire cord at a nearby position on an upstream side from a position where the unvulcanized rubber coats the twisted wire cord
Implementation Method 2
coating unvulcanized rubber extruded by the rubber extruder on an outer circumferential surface of the twisted wire cord that is moving
Data Source
AI summary
In a method of manufacturing a rubber coated twisted wire cord, when an outer circumferential surface of a twisted wire cord that is moving from an unreeling unit to a winding unit is coated with unvulcanized rubber extruded by a rubber extruder, by a coating unit disposed between the unreeling unit and a winding unit, in a state of additional tension being imparted on the moving twisted wire cord by a tension imparting unit disposed at a nearby position on an upstream side from the coating unit in a moving direction of the twisted wire cord, the unvulcanized rubber coats the outer circumferential surface of the twisted wire cord in this state to continuously manufacture a rubber coated twisted wire cord.