Topping Sheet Formation by Wire-Splitting Rolled Cord Fabric

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Solution Overview

Problem

Existing methods for forming a narrow topping sheet for pneumatic tire carcass ply production are inefficient, as they either struggle with cutting wide textile original fabrics or require labor-intensive setup of multiple cord bobbins, leading to complex production control and space constraints.

Innovation Solution

A method involving cylindrical winding and cutting of textile original fabrics using a wire wound at a predetermined angle to divide the fabric into narrow sections, which are then topped with unvulcanized rubber, allowing for simultaneous feeding and division without the need for a separate cord original fabric preparation step, thus reducing equipment requirements and production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a wide textile original fabric is topped with unvulcanized rubber to form a wide topping sheet, then the topping sheet can be formed, but dividing this sheet widthwise is not easy and calender line increases in size

Engineering Contradiction:

Improveease of dividing topping sheetVSAvoidcalender line size

Core Design Contradiction:

Ease of manufactureVSArea of stationary object

Solution Approach 1:

The invention divides the wide textile original fabric into multiple narrow textile original fabrics before the topping process. This segmentation is achieved by cylindrically winding the fabric and cutting it with a wire at predetermined positions. By performing division before topping, the calender line size remains small and manageable, avoiding the problem of having to divide a already-formed wide topping sheet.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If tire cords are supplied from a large number of cord bobbins to form a narrow cord original fabric, then the narrow topping sheet can be formed, but it takes labor to set the large number of cord bobbins

Engineering Contradiction:

Improveease of forming narrow topping sheetVSAvoidnumber of cord bobbins

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The invention uses a single wide textile original fabric that serves multiple purposes. Instead of requiring multiple cord bobbins to form narrow fabrics, one wide fabric is divided into multiple narrow fabrics through cylindrical winding and wire cutting. This multi-functional approach allows one fabric source to produce multiple topping sheets, eliminating the need for multiple cord bobbins and reducing setup labor.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Area of stationary object

If the topping sheet is configured to have a narrow width to satisfy compact apparatus configuration, then space constraint is met, but the topping sheet must be formed by dividing a wide sheet or using multiple cord bobbins

Engineering Contradiction:

Improveapparatus arrangement spaceVSAvoidefficiency of forming narrow topping sheet

Core Design Contradiction:

Area of stationary objectVSProductivity

Solution Approach 1:

The invention performs the division of the wide textile original fabric into narrow fabrics as a preliminary action before the topping process. By cutting the wide fabric into narrow strips while it is in the textile original fabric state (before rubber topping), the subsequent topping process can be performed on already-divided narrow fabrics. This preliminary division enables compact apparatus configuration while maintaining high productivity, as the division is done efficiently through cylindrical winding and wire cutting.

Inventive Principle:

Principle #10Preliminary action

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 enables efficient formation of narrow topping sheets by reliably cutting weft yarns and eliminating the need for additional equipment, resulting in space savings and reduced production costs while ensuring accurate feeding and topping processes.

Implementation Method 1

cutting off the weft yarns in predetermined widthwise positions by using a wire wound on the original fabric roll in a predetermined winding angle range

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Implementation Method 2

topping at least one surface of each of the narrow textile original fabrics with unvulcanized rubber

Methodology Applied

Scientific EffectCoating/Deposition: Deposition (physical)

Data Source

PatentUS9944034B2Method of forming topping sheet and apparatus thereof

Publication Date: 2018.04.17 TOYO TIRE CORP

AI summary

A topping sheet forming method includes: a division step of cylindrically winding a textile original fabric, obtained by weaving longitudinally aligned tire cords into a cord fabric by use of weft yarns, to form an original fabric roll and cutting off the weft yarns in predetermined widthwise positions by using a wire wound on the original fabric roll in a predetermined winding angle range to divide the textile original fabric into narrow textile original fabrics; and a topping step of topping at least one surface of each of the narrow textile original fabrics with unvulcanized rubber.