Tyre Winding With Localized Pitch Gap For Conductive Insert
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Solution Overview
Problem
The existing methods for manufacturing tires with non-conductive filler materials, such as silica or low black carbon, face inefficiencies in establishing electrical conductivity for electrostatic charge dissipation, particularly when the underlayer is not conductive, requiring multiple steps and interrupting the winding process to insert conductive paths.
Innovation Solution
A method that creates a localized pitch difference in the underlayer winding process to allow continuous winding without interrupting the process, enabling the insert to contact the crown reinforcement ply during vulcanization, establishing an electrically conductive path for electrostatic charge dissipation without the need for contiguous turns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the underlayer is formed of non-conductive rubber material, then the manufacturing process requires interrupting the winding operation to insert the conductive insert, but this increases the number of elementary sequences and reduces production efficiency
Solution Approach 1:
The underlayer is pre-formed with a localized pitch difference (gap) at the position where the conductive insert will be placed. This preliminary preparation allows the insert to be integrated during continuous winding without stopping the machine, as the gap is already positioned correctly to receive the insert material.
Solution Approach 2:
The localized pitch difference in the underlayer acts as an intermediary structure that facilitates the insertion of the conductive insert. The gap created by the pitch difference serves as a receptacle for the insert, enabling electrical connectivity between the tread and crown reinforcement plies while maintaining continuous production.
2Reliability
If the winding process is interrupted to insert the conductive insert, then the insert can be properly positioned to contact the crown reinforcement ply, but this increases device complexity and operational complexity
Solution Approach 1:
The position for the conductive insert is predetermined and prepared in the underlayer before the winding operation begins. The pitch difference is created at the exact location where the insert needs to contact the crown reinforcement ply, eliminating the need for complex positioning operations during the winding process.
Solution Approach 2:
The underlayer structure itself provides the mechanism for insert placement through its pitch difference. The gap in the underlayer automatically positions the insert correctly as it is deposited, without requiring additional positioning devices or complex operational procedures.
3Manufacturing precision
If multiple elementary sequences are used for depositing underlayer and insert separately, then precise positioning can be achieved, but this increases the number of operations and reduces manufacturing efficiency
Solution Approach 1:
The deposition of the underlayer and the conductive insert are merged into a single continuous winding operation. The pitch difference in the underlayer ensures that the insert is deposited at the correct position in the same operational sequence as the underlayer, achieving both precision and efficiency.
Solution Approach 2:
The pitch difference is pre-established in the underlayer to mark the exact position where the insert should be deposited. This preliminary positioning guide allows the insert to be placed accurately during the continuous winding process without requiring separate positioning 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 reduces the number of elementary sequences in tire production, allowing continuous winding of the underlayer and reducing production complexity while maintaining effective electrostatic charge dissipation through the tire.
Implementation Method 1
establishing an electrically conductive path for electrostatic charge dissipation
Data Source
Figure 1~3
Figure 4~8
AI summary
Method of manufacturing a tyre (1) by winding contiguous strips around a rotary form with a pitch and a number of turns adapted to the desired profile, comprising the following steps in which a strip intended to form the underlayer (13) is deposited on the plies (15) forming the crown reinforcement belt, said strip being produced from a weakly electrically conductive rubbery material, one or more strips intended to form the first part of the tread (11A), positioned axially on one side of the tyre preform, said strip or strips being produced from weakly electrically conductive rubbery materials, one strip intended to form the insert (10) arranged so that at least one radially internal turn (100) is in contact with the underlayer (10), said strip being produced from an electrically conductive rubbery material. A localized pitch gap (130) is created during the winding of the strip that forms the underlayer (13), said pitch gap being positioned axially to the right of the radially internal part of the insert (10) so as to render the turns non-contiguous.