Vacuum Forming Elastomeric Tire Core Using Deep Vacuum Canister
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Solution Overview
Problem
Existing methods for vacuum forming elastomeric tires with cores of belts, plies, and beads often result in tires with voids or projections due to trapped air, leading to cosmetic anomalies and an uneven surface finish.
Innovation Solution
A vacuum forming apparatus that removes air from the elastomeric material mixture before it enters the mold, using a deep vacuum canister connected to a low-level vacuum mold cavity, ensuring the material fully encapsulates the core and fills all voids, resulting in a homogenous, balanced tire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If air is vented from the mold cavity early in the casting process through spaced holes, then air can be removed from the cavity, but materials from the tread flow into the holes and form projections or 'tits' on the tread surface
Solution Approach 1:
The patent applies preliminary action by evacuating air from the elastomeric material mixture before introducing it into the mold cavity. The deep vacuum canister removes air from the mixture in advance, so when the material is introduced into the mold, it is already air-free and can fully encapsulate the core without forming voids or projections.
2Device complexity
If a single vacuum source is used to evacuate air from the mold cavity, then the apparatus is simpler, but air and other fluids become trapped between the tire and the cavity surface
Solution Approach 1:
The patent segments the vacuum system into two distinct parts: a deep vacuum canister for removing air from the elastomeric material mixture, and a low-level vacuum mold cavity for pulling the air-free mixture through the mold. This segmentation allows each vacuum source to perform its specific function effectively, ensuring complete air evacuation without trapping air between the tire and cavity surface.
3Productivity
If the elastomeric material is introduced into the mold without pre-removal of air, then the process is faster, but voids or pockets form in the finished tire
Solution Approach 1:
The patent applies preliminary action by evacuating air from the elastomeric material mixture before introducing it into the mold cavity. The deep vacuum canister removes air from the mixture in advance, so when the material is introduced into the mold, it is already air-free and can fully encapsulate the core without forming voids or projections.
4Device complexity
If the elastomeric material flow is not pulled through the core of plies, belts and beads, then the molding process is simpler, but the tire core is not optimally positioned and the tire is unbalanced
Solution Approach 1:
The patent uses pneumatic principles by employing a low-level vacuum in the mold cavity that pulls the air-free elastomeric material through the core of plies, belts, and beads. This pneumatic action ensures the material fully encapsulates the core and optimally positions it, resulting in a balanced tire while maintaining a relatively simple molding process.
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
The apparatus produces a tire with a smooth, unblemished surface and a perfectly balanced core of plies, belts, and beads, eliminating voids and projections, and allowing for a single operation molding process.
Implementation Method 1
A vacuum forming apparatus that removes air from the elastomeric material mixture before it enters the mold, using a deep vacuum canister
Implementation Method 2
using a deep vacuum canister connected to a low-level vacuum mold cavity, ensuring the material fully encapsulates the core and fills all voids
Data Source
AI summary
A vacuum forming process for manufacturing a transport tire from an elastomeric material that include steps of: in a mold having a cavity or annular area, positioning a transport tire core of plies, belt and beads that has been laid-up on a mandrel. Fitting a cover in sealing engagement over the mold top and fitting a cylindrical canister, that is open at a top end, through the center of the cover and into the mold center and pouring an elastomeric material mixture into the canister that includes a needle valve in its lower end that exhausts into one end of the mold annular area. The cylindrical canister includes a port for connection to a deep vacuum source and the cover includes a port that is for connection to a low level vacuum source, where the deep vacuum is to remove air from the elastomeric material mixture, and, after filling, is open to atmosphere, and the needle valve is opened to the mold annular chamber allowing the mixture to be pulled by the low level vacuum through the mold annular cavity, impregnating the transport tire core maintained therein.