Tyre Sidewall Coupling via Drum Shaping and Coiled Elements
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Solution Overview
Problem
The existing tyre manufacturing processes face challenges in achieving reliable coupling between the sidewall and tread interfaces, particularly with the 'underlying sidewall' configuration, which is prone to undesirable separations and structural deformations during the shaping step, and the 'overlying sidewall' configuration is more reliable but complicated to construct.
Innovation Solution
The process involves forming the sidewalls directly on a cylindrical carcass sleeve using continuous elongated elements wound into coils, allowing the carcass sleeve to be shaped without being removed from the building drum, with the application diameter being larger than the fitting diameter, and the sidewalls are coupled to the tread band in an 'underlying' configuration to minimize stretching and deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the 'underlying sidewall' configuration is used to simplify construction, then ease of manufacture is improved, but reliability deteriorates due to undesirable separations at the sidewall-tread interface
Solution Approach 1:
The patent changes the geometric parameters of the building drum, specifically using an application diameter larger than the fitting diameter. This parameter change allows the sidewalls to be formed on a larger diameter and then the entire structure to be shaped down, reducing stretching at the critical sidewall-tread interface while maintaining the simpler underlying configuration
Solution Approach 2:
The sidewalls are formed preliminarily on the building drum before the shaping operation. By forming the sidewalls in their final configuration on the drum and then shaping the entire assembly, the critical junctions are established before any stretching occurs, preventing separations
2Ease of operation
If the carcass sleeve is shaped by removing it from the building drum, then ease of operation is improved, but manufacturing precision deteriorates due to structural deformations
Solution Approach 1:
The patent merges the shaping operation with the building drum by providing shaping members that are operatively engageable directly to the drum. This allows the carcass sleeve to be shaped in-situ without removal, eliminating handling and repositioning that could cause deformations, while maintaining ease of operation through integrated functionality
Solution Approach 2:
The building drum is designed with multi-functionality, serving both as the support for forming the carcass sleeve and as the platform for shaping operations. The shaping members can be engaged to the drum, allowing the same device to perform multiple critical functions without transferring the workpiece
3Reliability
If the application diameter is made larger than the fitting diameter to reduce stretching, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent introduces dynamic capability to the building drum through shaping members that can be engaged and disengaged. The drum transitions from a static support to a dynamic system that can adapt its configuration, allowing the larger application diameter for forming while maintaining flexibility for different production needs
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 ensures a strong, reliable junction between the sidewalls and tread band with reduced structural and surface discontinuities, minimizing the risk of sidewall tearing and deformations, while maintaining production flexibility and quality.
Implementation Method 1
a building drum (10) having two axially approachable halves and having an outer circumferential surface defining an application diameter
Implementation Method 2
simultaneous admission of fluid under pressure into the carcass sleeve, so as to determine radial expansion of the carcass plies until causing adhesion of same against the inner surface of the outer sleeve
Implementation Method 3
a vulcanisation and moulding treatment is generally executed which aims at determining the structural stabilisation of the tyre through cross-linking of the elastomeric compounds
Data Source
AI summary
A carcass ply is applied around an outer surface of a building drum according to an application diameter larger than the fitting diameter of a tyre. Coaxially engaged around each of the end flaps is an annular anchoring structure defining the fitting diameter. A pair of sidewalls is manufactured by laying of a continuous elongated element in the form of approached coils on the carcass sleeve. An outer sleeve, including at least one belt structure possibly associated with a tread band, is coaxially centered around the carcass sleeve. Through axial approaching of two halves forming the building drum, the carcass sleeve is shaped into a toroidal configuration to determine application of same against a radially internal surface of the outer sleeve.