Calendering for Tire Production

Green tire production method to enable larger sidewall protrusions without increasing weight or rolling resistance. The method involves locally reinforcing the sidewall rubber in regions with protrusions during green tire production. After forming the tire carcass, sidewall rubber is wound onto the outer surfaces. Then, a band-shaped reinforcement is attached to specific areas on the sidewalls where protrusions will be molded. This provides extra thickness at those points without excess in other areas. When the green tire is vulcanized, the reinforcements align with recesses in the mold to form the protrusions. This allows larger sidewall features without over-thickening the sidewalls overall.

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Calendering and molding equipment with temperature adjustment to control roller temperatures for consistent material processing. The equipment has two opposing calendering rolls, each with a temperature regulating device attached. The temperature regulating devices contain multiple rollers with internal cooling channels. They can be adjusted and buffered using an external bracket. This allows precise temperature control on each roll to prevent material sticking or deformation during calendering.

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A rubber calendering device that improves quality and efficiency of rubber calendering by eliminating the need for preheating and reducing calendering time. The device has multiple calendering rolls below a feeding roll. Heating blocks in the lower rolls preheat the rubber before it is compressed and calendered. This prevents dissipation of heat during placement, which can cause calendering defects. The heated rubber is pushed through and cut off by the lower rolls, then moved to the upper rolls for calendering. This allows immediate calendering without waiting for the rubber to warm up.

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Controlling fluid discharge during tire molding to improve vulcanization and prevent defects. The method involves building the green tire with a radially internal surface that has channels or grooves extending from the belt to the sidewall. These channels connect to the mold's discharge channels. This allows fluids between the mold and green tire to flow out, preventing trapped air pockets and improving adhesion during vulcanization. The channels can be continuous elastomeric coils wound into the tire.

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Rubber compositions for tires that provide improved green tire processing and reduced scorching during manufacturing. The compositions contain functionalized elastomers with polar groups like hydroxyl, carbonyl, imine, and epoxide groups. They also have a polyphenolic compound like gallotannins with multiple vicinal hydroxyl groups. The functionalized elastomers crosslink independently of the rest of the elastomer structure. This allows better green processing and reduced scorching compared to traditional vulcanization systems. The compositions can be used in tires with reinforcing elements like metal-coated textile threads. The metal-coated threads have a metallic surface made of iron, copper, tin, zinc, brass, or steel. This improves adhesion between the reinforcing element and the rubber composition.

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Energy-efficient rubber track processing method for reducing wear, improving durability, and reducing environmental impact compared to traditional rubber tracks. The method involves mixing specific ratios of styrene-butadiene rubber, silicone rubber, natural rubber, carbon black, bentonite, hydroxyethyl cellulose ether, castor oil, peroxide, antifungal agent, UV absorber, initiator, accelerators, and anti-aging agent. The mixed material is calendered and vulcanized into sheets, then trimmed, polished, and packed for use as the energy-efficient rubber track.

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A tire with a shaped tread and a method of making it. The tire has a green tread made of sheets of polymeric material. The sheets have a tread region and are sandwiched between upper and lower rings with spokes extending between them. The green tread is then cured to form the final tire tread. This allows for a more efficient and cost-effective tire manufacturing process compared to traditional methods.

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An auxiliary device for improving rubber calendering processes. The device has a fixed box with a molding press hole and two sets of figure-eight shaped rolling spokes inside. One set has fixed gears at the top and universal joints at the bottom. The other set has worms at the bottom connected to a motor. This allows synchronized, coordinated movement of the spokes to evenly press the rubber between them, preventing uneven widths and improving sheet quality.

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Automobile tire manufacturing and processing technology that reduces waste, improves efficiency, and simplifies processing steps compared to traditional methods. The technology uses an automated tire manufacturing machine with features like a stirring device, calendering device, and specialized barrels. The stirring device has a rotating column with screw belts to agitate and melt the rubber. The calendering device has spiral-wrapped cylinders with adjustable lengths and angles to control the thickness and shape of the extruded rubber. This allows precise calendering without trimming or scraping, as the cylinders can be quickly swapped out. The stirring and calendering steps are integrated into the machine to minimize waste and simplify processing. The stirring device scrapes and filters the rubber before extrusion, and the calendering device has features like arc-shaped grooves and adjustable spacing to optimize processing.

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A production process for improving the elasticity of rubber cloth by using a specific calendering and vulcanization sequence. The process involves initially calendering the rubber between two rolls, then conveyor belt transport followed by vulcanization on a drum. The final calendering step is done after vulcanization using the original calendering rolls to further shape the rubber. This sequence reduces viscosity and deformation issues compared to traditional pressing-vulcanization-calendering methods.

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A tire belt laminating process that reduces belt sticking and improves belt quality during tire manufacturing. The process involves using a four-spoke calender with specific temperature settings to bond rubberized steel wire. The rubber supply temperature is 95-105°C, the upper and middle spoke rollers are 60-70°C, the side spoke roller is 85-95°C, and the lower spoke roller is 85-95°C. The belt temperature is maintained at 80°C. This temperature profile reduces belt sticking, improves belt surface quality, and allows faster calendering speeds compared to traditional belt lamination processes.

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High-safety multi-roll calender that can quickly adjust the calendering state. The calender has features like oppositely turning calendering rolls, an adjusting mechanism with a jacking rod, a rubber hanging mechanism with separate cylinders and a rubber tube, and a winding mechanism. These features allow quick adjustment of calendering force, roll gap, and rubber thickness during processing.

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A concave-convex nested rubber calender with integrated laminating and forming capabilities. The calender has two parallel rollers, a first roller with bumps on its surface and a second roller with matching larger grooves. The rollers rotate at the same speed and the bumps fit into the grooves. This allows the rollers to simultaneously laminate and form the rubber materials. The concave-convex configuration provides a continuous process without separate steps for bonding and forming.

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Composite rubber with improved slip resistance for shoes and tires, and a method to manufacture it. The composite contains a tetrapod-shaped ceramic single crystal dispersed in the rubber matrix. The crystals significantly enhance friction and abrasion resistance compared to regular rubber. The composite is made by mixing the rubber, blending agents, and crystals, kneading, calendering, and molding.

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Vulcanizing compositions and processes for vulcanizing elastomers that provide improved thermal stability and processing conditions compared to conventional sulfur-based vulcanizing agents. The compositions contain a cyclododecasulfur compound as the vulcanizing agent, which has a high melting point and improved thermal stability compared to conventional insoluble sulfur. This allows higher processing temperatures and reduces the risk of premature crosslinking during mixing, extrusion, calendering, etc. The cyclododecasulfur vulcanizing agent enables faster processing speeds and better performance in elastomeric compounds compared to conventional sulfur vulcanizing agents.

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Solid master elastomeric composition containing nanoscale silicate fibers with needle-shaped morphology for improved tire performance. The masterbatch is prepared by dispersing the fibers in an elastomer latex, followed by coagulation to form a solid elastomeric composition. This allows uniform fiber distribution and control of fiber content in the final tire compound. The fibers provide reinforcement without adding carbon black. The masterbatch is added to the tire compound along with other elastomers, vulcanizing agents, etc. The tire components are then molded into green tires which are vulcanized to form the final tires. The fiber-reinforced tire compound has reduced hysteresis and improved rigidity compared to carbon black-reinforced compounds.

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A composite sheet formed by integrating a plain weave or leno weave fabric with a sheet structure through calendering. The fabric and sheet are superimposed and pressed between rotating rolls at high pressure and temperature to compact and bond them. This reduces the thickness of the composite sheet compared to bonding with adhesive. The calendered fabric has crushed threads and smaller apertures. The composite sheet retains strength and prevents mesh shift.

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A calender for profiling rubber compounds used in tire casings that reduces defects in the profiled sheets. The calender has three rolls with parallel axes where the lower and intermediate rolls are vertically aligned and the upper roll is angled. The lower and intermediate rolls form the main profiling nip, while the upper roll forms a secondary nip. After exiting the main nip, the profiled sheet goes onto a table to separate it further. This two-stage profiling with a separating table prevents lateral edge and cohesion defects in the profiled sheets that can occur with single-stage calendering.

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Method for manufacturing a sheet-shaped rubber member that can easily bring only one surface of the sheet into a semi-vulcanized state. It involves heating one surface of the rubber sheet using a contact heating device while cooling the other surface. The temperature difference between the heated surface and the cooled surface is 80°C or more. The heat history applied to the heated surface is 3-10 minutes at an equivalent vulcanization degree of 150°C. This selectively semi-vulcanizes one side of the rubber sheet to prevent cord biting in tires. The cooling prevents shrinkage.

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A method for manufacturing raw green tires with improved electrical conductivity inserts between the tread and carcass layers. The method involves simultaneously feeding rubber into the gap between two calendered layers to form the ply, while also continuously extruding rubber from nozzles extending from the sides of the calender into the gap. This creates conductive inserts between the ply layers. The nozzle rubber extends continuously from one ply to the next to maintain electrical conductivity through the tire.

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