Patent Application
20150239189
The present invention relates to a manufacturing method for a pneumatic tire having excellent uniformity and the pneumatic tire.
In recent years, a manufacturing method for a pneumatic tire to improve uniformity of the tire has been proposed. In this manufacturing method, for example, as shown in
The strip-shaped ply piece b1 is obtained by sequentially cutting a long ribbon-shaped ply b along a ply width direction. The ribbon-shaped ply b has an array (a) of a plurality of carcass cords a1 paralleled along the length direction thereof and a topping rubber c coating the array. The rigid core d has an outer shape approximate to, for example, the tire cavity shape of the finished tire.
As shown in
The tire (carcass ply) manufactured by such method has the mass which is even in the tire circumferential direction, and possesses excellent uniformity.
However, there is a tendency such that an intermediate elongation rate of a carcass cord al varies a little along the length direction due to unevenness of twisting during manufacturing and the like.
In a carcass ply k, in which a strip-shaped ply piece b1 cut out from a ribbon-shaped ply b employing such carcass cords al is applied continuously In the tire circumferential direction in the order corresponding to the cutting, the intermediate elongation rates of the carcass cords show variations continuously in the tire circumferential direction.
On the other hand, the first and last two ply pieces, between which the difference in the intermediate elongation rate becomes largest, are disposed adjacently to each other in the tire circumferential direction.
Therefore, in the above-mentioned position of the carcass ply k, a large variation of the intermediate elongation rate occurs, and there is a possibility that the tire uniformity is deteriorated.
There is a relevant art as follows.
Patent document 1: JP-P2012-106441A
The present invention was made with the view to the above-mentioned actual situation, and an object is to provide a manufacturing method for a pneumatic tire which can improve uniformity, and the pneumatic tire manufactured by the manufacturing method.
A first invention of the present invention is a manufacturing method for a pneumatic tire having a carcass extending from a tread portion to bead portions on both sides through sidewall portions, characterized by including
a green tire formation process in which a raw tire is formed by applying tire constructional members including an unvulcanized carcass ply onto an outer surface of a rigid core, and
a vulcanization process in which, within a vulcanization mold, the raw tire is vulcanization molded together with the rigid core, wherein
the green tire formation process includes
a ply piece forming process in which, by sequentially cutting a ribbon-like ply, which is an array of carcass cords paralleled along the length direction and coated with topping rubber, into specific lengths from its leading end,
a plurality of strip-shaped sheet-like first ply pieces are continuously formed, and thereafter,
a plurality of strip-shaped sheet-like second ply pieces are continuously formed, and
a carcass ply forming process in which, by using the first ply pieces and the second ply pieces, the unvulcanized carcass ply is formed,
the carcass ply forming process has
a first step in which, by applying the first ply pieces, in the order corresponding to the cutting, over one round at intervals in the tire circumferential direction,
a first carcass ply part, in which the first ply pieces and first spaced parts are alternated in the tire circumferential direction, is formed, and
a second step in which, successively from the first step, by applying the second ply pieces, in the order corresponding to the cutting, over one round at intervals in the tire circumferential direction,
a second carcass ply part, in which the second ply pieces and second spaced parts are alternated in the tire circumferential direction, is formed,
the second ply pieces are positioned at the first spaced parts,
the second spaced parts are positioned at the first ply pieces,
the second ply pieces are, on the tire equator, not overlapped with the first ply pieces, and
the second ply pieces are, in their radially inner end portions, directly overlapped with the first ply pieces.
In the first invention of the manufacturing method for a pneumatic tire, it is preferable that widths of the first ply pieces and the second ply pieces are 10 to 50 mm.
A second invention of the present invention is a pneumatic tire which is characterized by being formed by the above-mentioned manufacturing method.
In the second invention, it is preferable that the pneumatic tire is a run-flat tire provided in the sidewall portion with a side-reinforcing rubber layer composed of an inner side-reinforcing rubber part abutting on the inner surface of the carcass, and
an outer side-reinforcing rubber part abutting on the outer surface of the carcass.
In the carcass ply forming process of the manufacturing method for a pneumatic tire according to the present invention, the long ribbon-shaped ply is sequentially cut at the specific length from the leading end, whereby a plurality of the first ply pieces are formed.
Thereafter, the ribbon-shaped ply is sequentially cut, and a plurality of the second ply pieces are successively formed.
Then, the first ply pieces are sequentially applied onto the rigid core, in the order corresponding to the cutting, over one round at intervals in the tire circumferential direction.
Thereafter, the second ply pieces are applied, in the order corresponding to the cutting, at the positions of the first spaced parts between the first ply piece.
Thereby, the first ply pieces and the second ply pieces are applied alternately in the tire circumferential direction.
Namely, the ply pieces higher in the intermediate elongation rate and the ply pieces lower in the intermediate elongation rate are disposed alternately in the tire circumferential direction, and
the variations of the intermediate elongation rate are evened in the tire circumferential direction.
Accordingly, uniformity, especially, the radial force variation (RFV) which is a variation of force in the tire radial direction is improved.
In addition, the second ply pieces are not overlapped with the first ply pieces at the tire equator.
Thereby, the length in the tire radial direction, of the pneumatic tire (carcass ply) is evened in the tire circumferential direction.
Accordingly, as the variation in the tire radial direction becomes small, uniformity, especially, free radial run out (FRRO) is improved.
Further, the second ply pieces are, in the inner end portions in the tire radial direction, directly overlapped with the first ply pieces.
Thereby, the first ply pieces are strongly fixed to the second ply pieces, and the tire durability is improved.
[
A cross sectional view showing an embodiment of the pneumatic tire formed by the manufacturing method according to the present invention.
[
A cross sectional view illustrating the green tire formation process.
[
A cross sectional view illustrating the vulcanization process.
[
A figure conceptually illustrating the manufacturing method according to the present invention.
[
A perspective view showing a ribbon-like ply piece.
[
(A), (B) are a cross sectional view and a side view for explaining the first step of the carcass ply forming process.
[
(A), (B) are a cross sectional view and a side view for explaining the second step of the carcass ply forming process.
[
A cross sectional view showing the section of the carcass ply at the tire equator by developing it in a linear fashion.
[
A cross sectional view of the pneumatic tire formed, as a run-flat tire, by the manufacturing method according to the present invention.
[
(A) is a tire side view showing an order for applying ply pieces in a comparative example;
(B) is a tire side view showing an order for applying ply pieces in the embodiment.
[
(A), (B) are perspective views for explaining the conventional manufacturing method for a pneumatic tire using a rigid core.
Embodiment of the present invention will now be described in detail.
The pneumatic tire 1 has at least a carcass 6 extending from a tread portion 2 through sidewall portions 3 to bead portions 4 on both sides.
In this embodiment, shown as the pneumatic tire 1 is a passenger radial tire in which a belt layer 7 is disposed outside the carcass 6 in the radial direction and in the tread portion 2.
The carcass 6 is composed of a carcass ply 6A in which organic fiber carcass cords are radially arranged. The carcass ply 6A is toroidal, extending between the bead portions 4, 4, and its both end portions are not folded around bead cores 5 disposed in the respective bead portions 4. The bead core 5 has axially inner and outer core pieces 5i, 5o. The both end portions of the carcass ply 6A are sandwiched between the inner and outer core pieces 5i, 5o.
The inner and outer core pieces 5i, 5o are formed by winding a non-extensible bead wire 5a multiple times in the tire circumferential direction.
It is preferable that the outer core piece 5o has a rigidity higher than the inner core piece 5i.
For example, in the outer core piece 5o, the number of turns of the bead wire 5a is for example, 1.2 to 2.0 times that in the inner core piece 5i.
Thereby, the bending rigidity of the bead portion 4 is increased, while restricting the total number of turns of the bead wire 5a. consequently, steering stability and the like are improved.
on the outside of the bead core 5 in the tire radial direction, a tapered bead apex 8 having a rubber hardness of 80 to 100 degrees for example, is disposed in order to increase bead rigidity. The bead apex 8 in this embodiment includes an outer apex 8o disposed axially outside the carcass 6, and an inner apex 8i disposed axially inside the carcass 6.
In this specification, the rubber hardness is a durometer A hardness measured at 23 degrees C. by the use of a type A durometer according to JIS-K6253.
The belt layer 7 is composed of at least two plies of high modulus belt cords, e.g. steel cords and the like arranged at, for example, about 10 to 35 degrees with respect to the tire circumferential direction.
In this embodiment, the belt layer is composed of two radially inner and outer belt plies 7A, 7B.
The belt plies 7A, 7B are arranged so that the belt cords are mutually crossed between the plies, and possess high rigidity. Thereby, the substantially entire width of the tread portion 2 can be stiffly reinforced.
In this embodiment, in order to increase the high-speed durability, a band 9 is disposed radially outside the belt layer 7. The band 9 is formed by, for example, spirally winding a band cord, e.g. nylon cord or the like at an angle of not more than 5 degrees with respect to the tire circumferential direction.
A pair of right ad left edge band plies covering only the axial outer edge portions of the belt layer 7 and
a full band ply covering a substantially entire width of the belt layer 7 can be employed alone or in combination as the band 9. The band 9 in this embodiment is made up of a single full band ply.
On the inside of the carcass 6, a thin inner liner 10 forming the tire inner surface is disposed.
In the inner liner 10, air-impermeable rubber, for example, butyl rubber, halogenated butyl rubber and the like is employed in order to retain air filled in the tire cavity.
On the axially outside of the carcass 6, a sidewall rubber Sg forming the outer surface of the sidewall portion 3 is disposed.
On the radially outside of the band 9, a tread rubber Tg forming the outer surface of the tread portion 2 is disposed.
Further, a clinch rubber Cg is disposed radially inside and axially outside the bead core 5.
Next, a manufacturing method for the above-mentioned pneumatic tire 1 will be described.
This manufacturing method includes a green tire formation process K1 shown in
In the green tire formation process K1, a raw tire 1N is formed by applying unvulcanized tire constructional members sequentially onto the outer surface of the rigid core 20.
In the vulcanization process K2, the raw tire 1N is vulcanization molded within a vulcanization mold 24 together with the rigid core 20.
For example, the green tire formation process K1 includes
an inner liner forming process for applying a member forming the inner liner 10 onto the rigid core 20,
a carcass forming process for applying a member forming the carcass 6,
a bead core forming process for applying a member forming the bead core 5,
a bead apex forming process for applying a member forming the bead apex 8,
a belt forming process for applying a member forming the belt layer 7,
a band forming process for applying a member forming the band 9,
a sidewall forming process for applying a member forming the sidewall rubber Sg,
a tread forming process for applying a member forming the tread rubber Tg and the like.
The rigid core 20 has an outer shape which substantially coincides with the tire cavity shape of the pneumatic tire 1.
As for the other processes of the green tire formation process K1 than the carcass forming process and the vulcanization process K2, it is possible to arbitrarily employ known manufacturing techniques utilizing a rigid core 20.
In this specification, accordingly, only the carcass forming process is explained hereunder.
As shown in
a ply piece forming process for forming a plurality of strip-shaped sheet-like first ply pieces 13 and second ply pieces 14 by cutting a long ribbon-shaped ply 12, and
a carcass ply forming process for forming an unvulcanized carcass ply 6A by the use of the first and second ply pieces 13, 14.
In
For example, as shown in
a rubber extruder 31 for extruding the unvulcanized ribbon-shaped ply 12,
a first conveyor 34 for receiving the ribbon-shaped ply 12 from the rubber extruder 31 and conveying toward the downstream side at a specific conveying speed,
a cutter 35 for cutting the ribbon-shaped ply 12 into specific lengths, and
a second conveyor 36 for conveying the cut-out ribbon-shaped plies 12 to the rigid core 20.
For example, the rubber extruder 31 is of a screw type,
and has a nozzle die 32 for extruding the ribbon-shaped ply 12 in a specific shape.
As the first conveyor 34 and the second conveyor 36, for example, roller conveyors are employed.
As the cutter 35, for example, that having a cutting blade 35A, e.g. ultrasonic cutter or the like is employed.
The ply piece forming apparatus 30 in this embodiment is further provided with an accumulator section 37.
In order to maintain the shape of the ribbon-shaped ply 12 by absorbing the difference between the motion (inclusive of speed and timing) of the ribbon-shaped ply 12 on the upstream side and the motion on the downstream side,
the accumulator section 37 can temporarily accumulate the ribbon-shaped ply 12 between the rubber extruder 31 and the first conveyor 34 by slacking it in a U shape.
In
As shown in
The ribbon-shaped ply 12 being conveyed by the first conveyor 34 is sequentially cut along the ply-width direction into specific lengths from the leading end in the conveying direction by the use of the cutter 35.
Thereby, a plurality of strip-shaped sheet-like first ply pieces 13 are continuously formed.
Thereafter, the ribbon-shaped ply 12 is sequentially cut along the ply-width direction into specific lengths from the leading end in the conveying direction by the use of the cutter 35.
Thereby, a plurality of strip-shaped sheet-like second ply pieces 14 are continuously formed in succession.
As the first ply pieces 13 and the second ply pieces 14 are formed from one ribbon-shaped ply 12 as explained above, the ply widths W1 (shown in
Next, the carcass ply forming process is carried out. The carcass ply forming process is illustrated in
The carcass ply forming process is made up of a first step K1a (shown in
First, in the first step Kia, as shown in
As shown in
The second step K1b is carried out in succession to the first step K1a as shown in
In the second step K1b, the second ply pieces 14 are sequentially applied, in the order corresponding to the cutting, on the rigid core 20, over one round at intervals in the tire circumferential direction.
Thereby, a second carcass ply part 6Ao, in which the second ply pieces 14 alternate with second spaced parts 16 in the tire circumferential direction, is formed.
The length S2 in the tire circumferential direction of the second spaced part 16 becomes maximum at the position of the tire equator Co, and gradually decreases toward the inside in the radial direction.
As shown in
In the ply piece forming process in the present invention, a plurality of the first ply pieces 13 and a plurality of the second ply pieces 14 are continuously formed from the ribbon-shaped ply 12.
In the carcass ply forming process, the first ply pieces 13 are applied onto the rigid core 20.
Then, in succession thereto, the second ply pieces 14 are applied in the order corresponding to the cutting.
Thereby, the manufacturing time is short.
Further, as the first ply pieces 13 are positioned at the second spaced parts 16, and the second ply pieces 14 are positioned at the first spaced parts 15, the first ply pieces 13 and the second ply pieces 14 are applied alternately in the tire circumferential direction with no space therebetween in the tread portion 2.
Thereby, the ply pieces with higher intermediate elongation rates alternate with the ply pieces with lower intermediate elongation rates, and
variations of the intermediate elongation rate are evened in the tire circumferential direction.
Accordingly, uniformity, especially, the radial force variation (RFV), which is variation of force in the tire radial direction, is improved.
In
Accordingly, at the tire equator C, the second ply pieces 14 are not overlapped with the first ply pieces 13.
Thereby, at the position 6s of the outer end in the tire radial direction of the carcass ply 6A at the tire equator co (shown in
As the variation in the tire radial direction is decreased accordingly, uniformity, especially free radial run out (FRRO) are improved.
As shown in
Namely, in the carcass ply 6A, there are alternately formed two-layered parts 17 defined by the overlap portions J and single-layered parts 18 between the overlap portions J, J.
Thereby, the first ply pieces are strongly fixed to the second ply pieces, and the tire durability is improved.
In this embodiment, as the two-layered parts 17 extend inward and outward in the radial direction like ribs, rigidity in the tire radial direction and torsional rigidity in the circumferential direction are effectively increased.
Further, as the single-layered part 18 and the two-layered parts 17 appear alternately in the tire circumferential direction, the sidewall outer surface is corrugated, which can prevent a cut from spreading circumferentially at a moment.
Therefore, the pneumatic tire 1 manufactured by the manufacturing method in this embodiment is improved in the durability.
It is preferable that the ply widths W1, W2 (shown in
If the ply widths W1, W2 are small,
the number of the ply pieces 13, 14 is increased,
which requires a longer time for the application and invites a decrease in the production efficiency.
In contrast, if more than 50 mm, wrinkles become liable to occur during application, and there is a possibility that the production efficiency and the uniformity are deteriorated. Therefore, it is especially preferable that the ply widths W1, W2 are 20 to 40 mm.
As to the carcass cords 21, organic fiber cords, e.g. PET (polyethylene terephthalate), PEN (polyethylene naphthalate), rayon, nylon, aramid and the like are suitably used.
In
The side-reinforcing rubber layer 25 in this embodiment includes an inner side-reinforcing rubber part 25A abutting on the inner surface of the carcass 6, and an outer side-reinforcing rubber part 25B abutting on the outer surface of the carcass 6.
The inner side-reinforcing rubber part 25A has a main portion 25A1 rising from the inner core piece 5i.
The main portion 25A1 in this embodiment has a substantially crescent cross section extending inward and outward in the radial direction from a central portion having a maximum thickness, while gradually decreasing the thickness.
For example, an outer edge portion in the radial direction, of the main portion 25A1 is positioned axially inside the outer end of the belt layer 7.
In this embodiment, a sub portion 25A2 covering the inner core piece 5i is connected to an inner edge portion in the radial direction, of the main portion 25A1.
The outer side-reinforcing rubber part 25B has a main portion 25B1 rising from the outer core piece 5o.
The main portion 25B1 in this embodiment has an outside part extending outward in the radial direction from a central portion having a maximum thickness while gradually decreasing the thickness, and
an inside part extending inward in the radial direction from the central portion while maintaining a substantially constant thickness or gradually decreasing the thickness.
In this embodiment, an outer edge portion in the radial direction, of the main portion 25B1 is positioned axially inside the outer end of the belt layer 7 and axially outside the outer edge portion in the radial direction, of the main portion 25A1. In this embodiment, a sub portion 25B2 covering the outer core piece 5o is connected to an inner end portion in the radial direction, of the main portion 25B1.
Such side-reinforcing rubber layer 25 restricts the motion of the carcass 6 by sandwiching the carcass 6 between the inner and outer side-reinforcing rubber parts 25A, 25B, therefore, it is possible to effectively increase the tire's side rigidity. Therefore, the steering stability and durability during run-flat operation are significantly improved.
The tire 1R in this embodiment is not provided with a tapered bead apex 8 made of hard rubber. Therefore, the side rigidity is evened, and partial deformation during run-flat operation is controlled, and the run-flat durability is further improved. Further, as the sub portions 25A2, 25B2 are provided, the bead core 5 and the side-reinforcing rubber layer 25 are integrated, and the side rigidity is increased over a wider range.
Preferably, the rubber hardnesses of the inner and outer side-reinforcing rubber parts 25A, 25B are less than the above-mentioned bead apex 8, and a rubber having a hardness of 60 to 85 degrees is suitably employed.
The maximum thickness for the inner and outer side-reinforcing rubber parts 25A, 25B depends on the tire size and category. In the case of a passenger tire, a range of 2 to 10 mm is preferred. In this embodiment, the maximum thickness of the inner side-reinforcing rubber part 25A is more than the maximum thickness of the outer side-reinforcing rubber part 25B.
In this embodiment, the same rubber composition is used for the inner side-reinforcing rubber part 25A and the outer side-reinforcing rubber part 25B, but they may be differed from each other.
For either one or both of the inner and outer side-reinforcing rubber parts 25A, 25B, a short fiber reinforced rubber with short fiber mixed in the rubber may be employed.
As to the short fiber, organic fiber, e.g. nylon, polyester, aromatic polyamide, rayon, VINYLON, cotton, cellulosic resin, crystalline polybutadiene and the like, as well as inorganic fiber, e.g. metal fiber, whisker, boron, glass fiber and the like may be cited. These may be employed alone or as a combination of two or more kinds.
In a manufacturing method for the run-flat tire 1R, in advance of the first step K1a in the carcass forming process, a process in which a member for forming the inner side-reinforcing rubber part 25A is applied onto the rigid core 20 is carried out, and
after the second step K1b, a process in which a member for forming the outer side-reinforcing rubber part 25B is applied onto the outside of the a second carcass ply part 6Ao is carried out.
While description has been made of one particularly preferable embodiment of the present invention, the present invention can be carried out by modifying into various embodiments without being limited to the illustrated embodiment.
Passenger tires (tire size 215/45R17) having the structure shown in
In
In
The encircled numbers in
In the comparative example, the ply pieces were arranged, in the order of cutting, continuously in the tire circumferential direction without making the spaced parts.
Common specifications of the plies and test method were as follows.
<Ply piece>
ply width: 30 mm
ply thickness: 1.2 mm
number and diameter of carcass cords: rayon, 0.76 mm
number of carcass cords: 20
<uniformity>
For each tire, fifty samples were measured for low-speed RFV according to JASO C607: 2000 “TEST PROCEDURES FOR AUTOMOBILE TIRE UNIFORMITY”, and the average value was obtained.
The results are indicated by an index based on the average value of the comparative example 1 being 100. The smaller value means the better uniformity.
The tire measuring conditions are as follows.
wheel rim size: 8.0×17
inner pressure: 200 kPa
vertical load: 4.0 kN
tire revolution speed: 60 rpm
As shown in Table 1, it was confirmed that Embodiment tire was highly improved in the uniformity in comparison with Comparative example tire,
Further tests were made by changing the tire size and the shape of the ply piece, which gave the same result as of Table 1.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-185653 | Aug 2012 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2013/069525 | 7/18/2013 | WO | 00 |
