Patent Application
20090020204
The present invention relates to an air bladder for a safety tire which has a hollow toric body which is to be accommodated in a tire to form a cavity at least between the air bladder and an inner surface of a tread portion of the tire under the normal internal pressure state of the tire and to radially expand with a decrease in the internal pressure of the tire to take over load support from the tire, and to a safety tire using such an air bladder. Particularly, the present invention directs to reduce to prevent the inner surface of the air bladder from being stuck and to improve an air-impermeability of such an air bladder.
As a safety tire which can travel for a certain distance even under the runflat state where the tire internal pressure is suddenly lowered due to puncture or the like, known are a tire in which a reinforcing member such as a reinforcing tube, a reinforcing rubber and a reinforcing belt is used as a rubbery material or a forming body, an elastic body or a core is accommodated. More recently, a safety tire in which an air bladder having a hollow toric body is accommodated to radially expand with a decrease in the internal pressure of the tire to take over a tire load under the runflat condition where the internal pressure of the tire is decreased due to puncture or the like is getting widely used from the view point of suppressing a production cost and weight (see, for example, JP 2004-90808A).
Such an air bladder is typically manufactured in the following sequence. Firstly, as shown in
From this state, the bladders 102 are further inflated to bend the end of the air bladder body member 103 toward nearly right angle by means of the bladders 102, and thereafter cylindrical bodies 104 are displaced from outside toward inside of the width direction of the drum. The widthwise outer surfaces of the bladders 102 are pushed by the cylindrical bodies 104 and displaced toward inside of the width direction of the drum with the air bladder component member 103. As a result, as shown in
Subsequently, as shown in
During the manufacturing and storage after the manufacturing, mutually facing inner surfaces of the air bladder are likely to be contact with each other. For this reason, if unvulcanized rubber is used a the air bladder component member, the contacted portions are stuck with each other, which makes it impossible to fold the air bladder component member normally or causes a defect of the shape in the subsequent vulcanizing step. In order to prevent this, it has been employed to use partially vulcanized air bladder component member or apply a release agent such as stearic acid or silicone on the inner surface of the unvulcanized air bladder component member. However, when partially vulcanized rubber is used as the air bladder component member, the number of times for vulcanization is increased as compared with the case where unvulcanized rubber is used as the air bladder component member, which causes a problem that the production efficiency is decreased and the production cost is increased. On the other hand, when a release agent such as stearic acid is applied, a defect of melt adhesion is caused during the joining due to the release agent being caught between the joined surfaces of the ends of the air bladder body member, which remarkably decreases the durability of the air bladder and may cause an accumulation of the release agent scattered in the operation processes on the floor of the operation area to lead dirt of the operation area or an accident of the operator being slipped. In addition, it is highly time-consuming and decreases the productivity in building the air bladder that a solid release agent is uniformly applied without any unevenness.
Moreover, maintaining the internal pressure of the air bladder for a long term is an important object, and, to this end, it has been employed that the air bladder body member 103 is configured with an air-impermeable inner liner member and a pressure-maintaining member for maintaining the shape of the air bladder against the internal pressure filled in the air bladder, with the inner liner member being arranged to surround the entire surface of the hollow toric body. However, the internal pressure of the air bladder may be remarkably decreased after a long time, so that the air bladder may not sufficiently functions if the tire gets punctured after such a long time. Accordingly, it is demanded to further improve the air-impermeability (performance of preventing air permeation).
The present invention has developed in view of these problems, and its object is to provide an air bladder with higher air-impermeability which can prevent facing inner surfaces of an air bladder having a hollow toric body during manufacturing or storage from being stuck, and to proved a safety tire using such an air bladder.
<1> The present invention is an air bladder for a safety tire which is to be accommodated in a tire and filled with air at a given internal pressure to form a cavity at least between the air bladder and an inner surface of a tread portion of the tire under the normal internal pressure state of the tire and to radially expand with a decrease in the internal pressure of the tire to take over load support from the tire, said air bladder comprising a hollow toric body bearing a tension caused by the internal pressure and an air-impermeable layer arranged on inner surfaces of the hollow toric body to maintain the internal pressure of the air bladder, wherein at least a part of the inner surfaces are configured with an air-impermeable resin film layer for preventing the inner surfaces from being stuck with each other. As used herein, the term “the normal internal pressure state” refers to the internal pressure regulated for a safety tire accommodating the air bladder by an industrial specification, standard or the like such as JATMA, TRA and ETRTO which are effective in the area where the tire is manufactured, sold or used, and specified according to the load capacity. The term a “given internal pressure” of the air bladder refers to such an internal pressure that a cavity can be formed between the outer surface of the air bladder and the inner surface of the tire under the air-filled state that the normal internal pressure state is applied to the tire, and that the air bladder can radially expand with a decrease in the internal pressure of the tire to take over load support from the tire under the runflat state that the internal pressure of the tire has been lost, and the internal pressure is preferably equal to or up to 20% more than the given internal pressure.
<2> In the air bladder for a safety tire according to the above item <1>, the air-impermeable layer is preferably an inner liner layer of air-impermeable rubber.
<3> In the air bladder for a safety tire according to the above item <2>, supposing that A refers to the entire length of the inner surface in the widthwise section of the hollow toric body, B refers to an extending length of the inner liner layer along the inner surface, and C refers to an extending length of the resin film layer along the inner surface, it is preferable that the length B is larger than the length A, the length C is within a range of 0.5A to (2A-B), and the resin film layer is disposed outside of the region where the inner liner layers are overlapped.
<4> In the air bladder for a safety tire according to the above item <2> or <3>, an air permeability of the inner liner layer at 60 degrees C. is preferably within a range of 3.75×10−8 cm3*cm/(cm2*s*Pa) to 2.25×10−6 cm3*cm/(cm2*s*cm*Pa) and the thickness of the inner liner layer is preferably within a range of 0.3 mm to 5.0 mm.
<5> In the air bladder for a safety tire according to the above item <1>, the air-impermeable layer is configured by covering the entire inner surfaces of the hollow toric body with the resin film layer.
<6> In the air bladder for a safety tire according to the above item <5>, the resin film layer is preferably melt adhered to the hollow toric body.
<7> In the air bladder for a safety tire according to any one of the above items <1> to <6>, an air permeability of the resin film layer at 60 degrees C. is preferably within a range of 7.5×10−18 cm3*cm/(cm2*s*Pa) to 15×10−16 cm3*cm/(cm2*s*cm*Pa) and the thickness of the resin film layer is preferably within a range of 10 μm to 4.0 mm.
<8> In the air bladder for a safety tire according to any one of the above items <1> to <6>, a spud for fixing a valve for filling an internal pressure is preferable attached onto the inner surface of the resin film.
<9> In the air bladder for a safety tire according to any one of the above items <1> to <8>, a spud for fixing a valve for filling an internal pressure is preferable attached onto the inner surface of the resin film, and the resin film layer is arranged except for a spud-applying region to which the spud is to be attached.
<10> In the air bladder for a safety tire according to any one of the above items <1> to <9>, the resin film layer is selected from a group consisting of thermoplastic polyurethane resin, thermoplastic polyolefin resin, polyethylene resin, polypropylene resin, polybutadiene resin, polyvinylidene chloride resin and combinations thereof.
<11> In the air bladder for a safety tire according to any one of the above items <1> to <10>, a radial expansion suppressing layer for suppressing a radial change under the normal internal pressure state is preferably arranged on the radially outer surface of the hollow toric body. The radial expansion suppressing layer is preferably configured with a compound material of a fiber selected from an organic fiber including polyester and polyamide and a rubber, which makes it possible to function the radial expansion suppressing layer at a desired performance.
<12> The present invention is also a safety tire accommodates the air bladder for a safety tire according to any one of the above items <1> to <11>.
With the feature recited in the above item <1>, it is possible to prevent the mutually facing inner surfaces of the hollow toric body from being stuck with each other during manufacturing and storage, and to simultaneously enhance the air-impermeability.
With the feature recited in the above item <2>, the inner liner layer consisting of air-impermeable rubber is arranged on the inner surface of the hollow toric body, so that air-impermeability can be further enhanced by disposing a resin film on the inner surface of the inner liner layer.
With the feature recited in the above item <3>, supposing that A refers to the entire length of the inner surface in the widthwise section of the hollow toric body, B refers to an extending length of the inner liner layer along the inner surface, and C refers to an extending length of the resin film layer along the inner surface, the length B is larger than the length A, in other words, the width ends of the inner liner are overlapped and joined with each other, so that the joining is assured to prevent air from passing therethrough. In addition, the film layer is arranged outside of the region where the inner liner layers are overlapped with each other (in this state, the extending length C of the resin film layer is not more than (2A-B) which is calculated by subtracting the overlapping length (B-A) from the length A), so that the width ends of the inner liner layer can be directly placed one on the other without interposing the resin film layer therebetween to strengthen the joining portion. Furthermore, the length C is not less than a half of the length A, so that the inner surfaces can be securely prevented from being stuck with each other.
With the feature recited in the above item <4>, an air permeability of the inner liner layer at 60 degrees C. is within a range of 3.75×10−8 cm3*cm/(cm2*s*Pa) to 2.25×10−6 cm3*cm/(cm2*s*cm*Pa) and the thickness of the inner liner layer is within a range of 0.3 mm to 5.0 mm, so that the internal pressure can be maintained for a long time in a preferable manner. When an air permeability of the inner liner layer is more than 2.25×10−6 cm3*cm/(cm2*s*cm*Pa) or the thickness of the inner liner layer is less than 0.3 mm, it is difficult to maintain a sufficient internal pressure for a long time. On the other hand, when an air permeability of the inner liner layer is less than 3.75×10−8 cm3*cm/(cm2*s*Pa) or the thickness of the inner liner layer is more than 5.0 mm, the production cost is increased with the increase in the weight of the inner liner layer since the member constituting the inner liner layer is combined with an expensive special rubber.
With the feature recited in the above item <5>, an inner liner layer consisting of an air-impermeable rubber is not used and, instead, the resin film layer is configure to possess the function of the air-impermeable layer, so that a cost down and simplification of the process can be achieved with not providing the inner liner layer. In addition, the length A of the inner surface of the hollow toric body is more than the extending length C of the resin film layer along the inner surface, in other words, the resin film is so configured as to cover the entire inner surface of the hollow toric body, so that a prevention of mutual sticking of the inner surface of the air bladder and the sealing of the leakage of air to the surroundings can be simultaneously realized with a singly layer.
With the feature recited in the above item <6>, the air bladder for a safety tire is configured such that the resin film layer is melt adhered to the hollow toric body, which can prevent a gap during folding the hollow toric body and a misalignment between the resin film layer and the hollow toric body.
With the feature recited in the above item <7>, an air permeability of the resin film layer at 60 degrees C. is within a range of 7.5×10−18 cm3*cm/(cm2*s*Pa) to 15×10−16 cm3*cm/(cm2*s*cm*Pa) and the thickness of the resin film layer is within a range of 10 μm to 4.0 mm, so that it is possible to simultaneously realize the maintenance of the internal pressure for a long time and improvement of the operation efficiency in building the air bladder. When an air permeability is more than 15×10−6 cm3*cm/(cm2*s*cm*Pa) or the thickness of the resin film layer is less than 10 μm, the internal pressure of the air bladder cannot be maintained for a long time and thus the air bladder may not function as desired in the case of the tire getting punctured. On the other hand, when an air permeability is less than 7.5×10−18 cm3*cm/(cm2*s*Pa) or the thickness of the resin film layer is more than 4.0 mm, the stiffness of the resin film member becomes high and it is difficult to deform the resin film member during the building operation, so that the operation efficiency of the building operation is decreased.
With the feature recited in the above item <8>, a spud for fixing a valve for filling an internal pressure is attached onto the inner surface of the resin film, so that it is not necessary to arrange the resin film layer while avoiding the area to which the valve is to be attached and thus the productivity in the process of assembling the resin film layer during the building step can be improved.
With the feature recited in the above item <9>, a spud for fixing a valve for filling an internal pressure is attached onto the inner surface of the resin film, and the resin film layer is arranged except for a spud-applying region to which the spud is to be attached, so that the spud may be attached not onto the resin film layer but onto a member of another layer exposed to the inner surface and thud the spud can be attached without using an adhesive, which make the operation of attaching the spade easier.
With the feature recited in the above item <10>, the resin film layer is selected from a group consisting of thermoplastic polyurethane resin, thermoplastic polyolefin resin, polyethylene resin, polypropylene resin, polybutadiene resin, polyvinylidene chloride resin and combinations thereof, so that the resin film layer can prevent the sticking of the inner surfaces, improve an air permeability, and facilitate the operation of building the air bladder with taking advantage of property ranges of a tensibility, stiffness, surface property, air permeability and the like.
With the feature recited in the above item <11>, a radial expansion suppressing layer for suppressing a radial change under the normal internal pressure state is arranged on the radially outer surface of the hollow toric body, so that a radial deformation of the air bladder can be prevented to be maintained in a desired shape under the normal running state and can be inflated to support the tire when the tire gets punctured.
With the feature recited in the above item <12>, a safety tire comprising the air bladder having any one of the features recited in the above items <1> to <11> also has the above-mentioned feature(s), so that the mutually facing inner surfaces of the air bladder can be prevented from sticking with each other during manufacturing and storage and can simultaneously enhance an air-impermeability of the air bladder. This enables a driving over a certain distance under a runflat state where the internal pressure of the tire is suddenly decreased due to puncture of the tire or the like.
a) is a widthwise sectional view of the air bladder for explaining a step subsequent to the step shown in
a) is a plan view showing a spud, and
Embodiments of the present invention will be described with reference to the drawings.
In the section of the air bladder 10, the air-impermeable layer 5 is arranged to cover the entire circumferential face surrounding the hollow portion 11. If there exists even a small part which is not covered by the air-impermeable layer 5, an air impermeability of the air bladder is remarkably decreased.
The pressure maintaining portion 1 is arranged over the entire air bladder, and a radial expansion suppressing portion 2 is attached onto the outer surface of the hollow toric body along the circumferential direction of the drum. It is noted that the pressure maintaining portion 1 may be configured by rubber alone, or a compound material containing rubber and fibers. The radial expansion suppressing portion 2 is composed of rubber or the like, and has one or more reinforcing layer 3 within it. Inside the radial expansion suppressing portion 2, a plurality pairs of surface layers 4a, 4b are arranged on the reinforcing layer 3 in the radially outside. In this way, when the tire gets punctured and the air bladder 10 is inflated, the widthwise center of the air bladder firstly contact the inner face of the tire and therefore the air bladder 10 takes over the tire load support in a symmetric and well-balanced manner. That is, it is possible to achieve a stable runflat running in a state where the internal pressure of the tire is decreased due to puncture or the like, and a prevention of a failure in an early stage due to an inflation of the air bladder under the normal internal pressure of the tire.
The air-impermeable layer 5 of the present invention may consist of a resin film layer alone, or a combination of a resin film layer and inner liner layer. In this connection, the means of constituting the air-impermeable layer may be a case where a resin film layer is provided on the inner surface of the hollow toric body be means of thermal adhesion, or a case where an inner liner layer is attached onto the inner surface of the hollow toric body and then a resin film layer is provided on the inner surface of the inner liner layer by means of thermal adhesion. Among these, the first embodiment as shown in
The air permeability of the resin film resin layer 6 is preferable within a range of 7.5×10−18 cm3*cm/(cm2*s*Pa) to 15×10−16 cm3*cm/(cm2*s*cm*Pa) and the thickness of the resin film layer is within a range of 10 μm to 4.0 mm.
It is an essential requirement for the present invention to provide an anti-stick function to the resin film layer 6 as well as to have an air-permeable property. The former prevents the inner surfaces of the air bladder 10 from being stuck with each other during the manufacturing and storage of the air bladder 10.
As a material of the resin for preventing the resin films from being stuck with each other, polyvinylidene chloride resin film (e.g. Saran Wrap®) and polyvinylidene chloride resin may be recited by way of example.
Thereafter, as shown in
Then, a sheet-like member in which a hole is provided at the position where the valve will pass through as shown in
Furthermore, in order not to misalign the resin film member 6A with respect to the pressure-maintaining member 1A consisting mainly of rubber at the time of assembling the resin film member 6A, it is preferred that an adhesive is applied on the entire surface of the resin film, or that a resin film member 6A having a good adhesive property for rubber, or that the hollow toric body and the resin film member are thermally adhered. As a material which does not have a self sticking property but has a good adhesive property for rubber, the above-mentioned polyvinylidene chloride resin film (e.g. Saran Wrap®) and polyvinylidene chloride resin may be recited by way of example.
Subsequently, as shown in
In this connection, the threaded portion 8b is arranged to protrude from the bottom face 8d (diameter d) of the spud body 8a. The spud 8 is adhered onto the resin film member 6A by means of a adhesive in such a manner that the portion protruding from the bottom face 8d of the threaded member 8b is accommodated in the through hole 13.
Then, as discussed with reference to the prior art, the bladders 102 and the cylindrical body (not shown) is used to fold the both width ends of the resin film member 6A provided with the pressure-maintaining member 1A, and the width ends are joined with each other, as shown in
Thereafter, one or more reinforcing layer is wrapped around and a radial expansion-suppressing member 2A to be a radial expansion-suppressing portion 2 is assembled. The air bladder constituting member thus obtained is vulcanized and shaped to form the air bladder 10.
In this case, by making the entire length A of the inner surface surrounding the hollow portion 11 of the hollow toric body greater than the extending length B of the inner liner layer 7 along the inner surface, the overlapping length 18 (which is (B-A)) in the process of joining the width ends of the inner liner layer 7 with each other to form a hollow toric shape can be ensured.
In addition, by making the extending length C of the resin film layer 16 along the inner surface identical to or slightly smaller than the length (2A-B) which is obtained by subtracting the overlapping length (B-A) from the entire circumferential length A, the resin film layer 16 can be arranged over generally entire circumference of the inner liner layer 7 except for the overlapping portion. In this connection, the reason why the extending length of the resin film layer 16 is set to be shorter than that of the inner liner layer 7 to not extend to the overlapping portion is as follows. If the resin film layer 16 has a length identical to that of the inner liner layers 7, the resin film layer 7 may be interposed between the inner liner layers 7 to be joined thorough adhesion in the process of shaping the inner liner layers into a hollow torus, which makes the adhesion between the inner liner layers unreliable. As a result, it is likely to leak air from the portion where the adhesion is failed to the environment. An air permeability of the inner liner layer 7 is preferably within a range of 3.75×10−8 cm3*cm/(cm2*s*Pa) to 2.25×10−6 cm3*cm/(cm2*s*cm*Pa) and the thickness of the inner liner layer is preferably within a range of 0.3 mm to 5.0 mm. An air permeability of the resin film layer 6 is preferably within a range of 7.5×10−18 cm3*cm/(cm2*s*Pa) to 15×10−6 cm3*cm/(cm2*s*cm*Pa) and the thickness of the resin film layer is within a range of 10 μm to 4.0 mm.
It is also an essential requirement for the present invention to provide an anti-stick function to the resin film layer 6 as well as to have an air-permeable property. The former prevents the inner surfaces of the air bladder 10 from being stuck with each other during the manufacturing and storage of the air bladder 10.
In the case of the resin film layer 6 of the second embodiment, most of the inner surface is covered by the resin film layer 16, so that polyvinylidene chloride resin film (e.g. Saran Wrap®) and polyvinylidene chloride resin may be used. However, in the case of preventing the portion 18 which is not covered by the resin film layer 16 from being stuck, it is preferred to used a resin selected from a group consisting of thermoplastic polyurethane resin, thermoplastic polyolefin resin, polyethylene resin, polypropylene resin and a combination thereof, which do not stick to rubber.
Furthermore, in order not to misalign the resin film member 6A with respect to the pressure-maintaining member 1A consisting mainly of rubber at the time of assembling, it is preferred that an adhesive is applied on the resin film member 16A, or that a resin film member 16A having a good adhesive property for rubber is used. When thermoplastic polyurethane resin, thermoplastic polyolefin resin, polyethylene resin, polypropylene resin or the like which does not adhere to rubber is used, it is needed to preliminarily apply an adhesive. On the other hand, when the polyvinylidene chloride resin film (e.g. Saran Wrap®) and polyvinylidene chloride resin, it is not necessary to use an adhesive.
When a sheet-like resin film is wrapped around, as is the case with the first embodiment, the starting position of the wrapping has to be adjusted in such a manner that the hole 14 agrees with the through hole 13. In addition, after wrapping the resin film member 16A, an adhesive for joining the both ends of the sheet-like member in the circumferential direction of the drum is applied on at least one end of the both ends of the sheet-like member.
In this case, at least one of the width ends of the resin film member 16A is displaced inside of the width end of the inner liner member 7A to expose the overlapping portion 18 for joining the width ends of the inner liner member 7A with each other.
Then, as shown in
Thereafter, as explained above for the prior art, the bladders 102 and the cylindrical body (not shown) are moved to fold the both end portions of the inner liner member 7A on which the pressure-maintaining member 1A and the resin film member 16A are integrally assembled, so that both the width ends of the inner liner member 7A are overlapped and joined with each other. In this state, a gap exists between the ends of the resin film members, so that these ends can be crimped to be joined without interposing the resin film member 16A therebetween. This makes the joining more secure.
Subsequently, as is the case with those explained with reference to
Regarding the attachment of the spud 8 for installing the valve 9, the spud may be attached onto the resin film member 16A as shown in
a) is a sectional view showing how the spud 8 is attached in this alternative method, and
The air bladder 30 for a safety tire according to this embodiment is the same as the air bladder 20 according to the second embodiment in the point mentioned in the above, but differs in the point that the resin film layer 26 constituting the air-impermeable layer 25 extends only radially inside of radial positions Q1 and Q2 corresponding to the maximum width of the air bladder. This embodiment is an example in which the resin film layer 26 has it a primal function of preventing the inner surface of the air bladder 30 from being stuck with each other, and the function of preventing air in the hollow portion 11 from leaking to decrease the internal pressure is taken mainly by the inner liner layer and supplementary by the resin film layer 26.
The resin film layer 26 extends only inside of the radial positions corresponding to the maximum width in the widthwise sectional view, so that the extending length C is a half of or slightly longer than the entire length A of the circumference surrounding the hollow portion 11. This configuration ensures the prevention of the sticking of the inner surfaces as well as can suppress the resin film layer to the minimum volume.
As shown in
Several kinds of air bladders having a resin film layer are manufactured as examples and these examples are evaluated for air-impermeability and productivity in the building process. Further, an air bladder in which stearic acid is applied for the purpose of preventing stick in lieu of having a resin film layer is also manufactured and evaluated for the same properties above. The arranging ratios of the resin film in these examples are shown in Table 1.
The size of the tires accommodating these air bladders are 495/45R22.5. The inner liner layers are made of butyl rubber with the thickness of 1.0 mm and the air-permeability at 60 degree C. of 18.75×10−18 cm3*cm/(cm2*s*Pa). The resin film layers are made of thermoplastic polyurethane resin with the thickness of 50 μm and the air-permeability at 60 degree C. of 37.5×10−8 cm3*cm/(cm2*s*Pa).
In Table 1, the arranging ratio of the resin film refers to the ratio C/A of the extending length C of the resin film layer along the inner surface surrounding the hollow portion to the entire circumferential length A of the inner surface in the widthwise section of the air bladder constituting the hollow toric body. In a case where the resin film layer is arranged, it is arranged to extend from the inside in the radial direction to the radial positions symmetrical in the widthwise section (for example, Q1 and Q2 in
In addition, the productivities in the building process are evaluated by measuring the building time required for building one air bladder. The results are shown in index values by using the inverse number of the measured building time with the result of Comparative example being set to 100. The greater index value means shorter building time and higher productivity. The building time is the time measured from the beginning of wrapping the air bladder constituting member on the building drum to taking it off from the building drum.
As can be clearly seen in Table 1, Examples are superior to Comparative example in both of the airtightness and productivity.
In terms of the sticking prevention property, those having no defect in manufacturing are used for all of Comparative example and Examples 1-4 and this is verified one week after the air bladder being built, by checking the presence of sticking between the inner surfaces and by checking the presence of peeling of the joining portion between the resin film layer and the inner liner layer.
An air bladder according to the present invention is applicable to various kinds of pneumatic tires having different sizes and structures.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2005-175154 | Jun 2005 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2006/312045 | 6/15/2006 | WO | 00 | 12/10/2007 |
