Patent Grant
7306019
This invention relates to a rubber composition of a foamed rubber providing a large friction force even on a body having, for example, an ice face of a low friction coefficient, and a pneumatic tire having improved steering stability performances such as braking performance, cornering performance and the like by applying this rubber composition to an upper-layer rubber part of a tread rubber constituting at least a ground contact face to enhance a gripping force on a frozen road surface or a snow covered road surface, particularly a winter-seasoned tire such as a studless tire or the like as well as a method of producing such a tire.
In the conventional pneumatic tires, particularly winter-seasoned tires such as studless tire or the like, there are proposed various methods for ensuring performances on ice or performances on snow.
As a way for increasing a friction coefficient on an ice-snow road surface, it is useful to microscopically form grooves by using a short fiber-containing foamed rubber as a tread rubber and breaking away the short fibers exposed on a surface of the tread accompanied with the wearing of the tread rubber during the running as described in JP-A-4-38207.
However, the microscopic grooves formed on the tread are liable to be crushed as a load applied to the tire becomes large, and hence the effect of increasing the friction coefficient on the ice-snow road surface can not be sufficiently obtained.
Also, it is necessary that the short fibers are embedded in the foamed rubber at a state of extending in a straight line and substantially in parallel to a worn face of the tread when the tread is worn by the running for rapidly breaking away the short fibers exposed on the worn face of the tread to microscopically form the grooves.
However, the short fibers are actually and frequently embedded in the foamed rubber at a state of being curled through heat shrinkage in the vulcanization or pushing the fibers into a groove portion of a mold part or a sipe portion to bend in the tread rubber. In this case, even if the tread worn during the running, the short fibers not extending substantially in parallel to the worn face of the tread can not easily be broken away from the foamed rubber, so that the microscopic grooves as originally intended can not be formed efficiently.
As another way for ensuring the performances on ice or performances on snow, it is useful to use a foamed rubber containing spherical closed cells in the tread as described in JP-A-62-283001.
That is, ice or snow on the ice-snow road surface is thawed to water by friction heat when the tire tread contacts with the ice-snow road surface and this water forms a water membrane between the tread and the ice-snow road surface, and the performances on ice or performances on snow are deteriorated by this water membrane. In case of the tire using the above foamed rubber, the water membrane can be removed by the action of irregularities on the tread formed by the closed cells, and hence it is attempted to improve the performances on ice or the performances on snow.
However, the tire described in JP-A-62-283001 does not develop the sufficient water-removing effect because the irregularities formed on the tread by the closed cell are very fine.
For this end, the applicant has made studies for enhancing the water removing effect on the ice-snow road surface and found that the water removing effect on the ice-snow road surface is conspicuous in pneumatic tires provided with a tread having not only the spherical closed cells but also many continuous closed cells covered with a protection layer of a resin, which has been proposed by an Application No. JP9700873 of an international application under PCT (international publication No. 9734776).
In such a tire, it is considered that drainage paths can be particularly formed by the continuous closed cells, whereby the water removing effect is enhanced.
However, the applicant has made further studies in order to more enhance the water removing effect on the ice-snow road surface and revealed that there is room for improvement because it is hardly said that the sufficient drainage paths are formed in the tire as the length of the continuous closed cell is shorter than an arranging pitch of sipe or groove disposed on the tread.
It is an object of the invention to provide a rubber composition giving a large friction force on a body having, for example, an ice face of a low friction coefficient by constituting with a foamed rubber having a rationalized cell-existing state, and a pneumatic tire having improved steering stability performances such as braking performance, cornering performance and the like by applying this rubber composition to at least an upper-layer rubber part of a tread rubber constituting a ground contact face to enhance a gripping force on a frozen road surface or a snow covered road surface, particularly a winter-seasoned tire such as a studless tire or the like as well as a method of producing such a tire.
In order to achieve the above object, the first invention is a rubber composition constituted with a foamed rubber, characterized in that the foamed rubber has continuous cells each continuously extending substantially along a particular direction and sealed with a resin protection membrane.
Also, it is preferable that the foamed rubber comprises resin cords continuously extending in a thready form along a particular direction before vulcanization and a foaming agent, in which the resin cord is melted in the vulcanization to develop a viscosity lower than that of rubber constituting the foamed rubber and the foaming agent has a property of foaming in the vulcanization to produce gases, and the continuous cell is formed by sealing at least a part of gases produced from the foaming agent with the resin protection membrane made of the resin cord.
The second invention is a pneumatic tire comprising a tread rubber, at least an upper-layer rubber part of which forming a ground contact face being made of a foamed rubber, characterized in that the upper-layer rubber part has toroidally continuous cells each continuously extending substantially along a circumferential direction of the tire and sealed with a resin protection membrane.
It is preferable that the foamed rubber comprises resin cords each continuously extending in a thready form along the circumferential direction of the tire before vulcanization and a foaming agent, in which the resin cord is melted in the vulcanization to develop a viscosity lower than that of rubber constituting the upper-layer rubber part and the foaming agent has a property of foaming in the vulcanization to produce gases, and the continuous cell is formed by sealing at least a part of gases produced from the foaming agent with the resin protection membrane made of the resin cord. Also, it is preferable that the continuous cells are arranged at plural stages in a thickness direction of the tread.
The resin cord is preferable to have a cord diameter of 10-100 μm and/or to have a melting point lower than a maximum vulcanization temperature of the tread rubber.
The foamed rubber is preferable to have long cells of 0.5-5 mm in length in addition to the above continuous cells, in which these long cells are arranged so as to connect with the continuous cells in a network form and/or to have an existing ratio of all bubbles contained in its interior of 10-40% as a weight ratio and HD (hardness) of 38-58.
Moreover, the term “HD (hardness)” used herein means a scale reading of a durometer hardness as measured at a testing temperature of 20° C. by a type-A durometer hardness testing machine defined in JIS K6253-1993.
The upper-layer rubber part is preferable to have a thickness corresponding to 30-70% of a thickness of the tread rubber.
The third invention is a method of producing a pneumatic tire which comprises covering one or plural resin cords arranged in parallel to each other with a foamed rubber containing a foaming agent to form a sheet-like member having a given width, winding and laminating the sheet-like member on a green case or a shaping drum along a circumferential direction of the green case or the shaping drum to form an upper-layer rubber part constituting a tread rubber and vulcanizing, during which the resin cord is melted to form a resin protection membrane and at least a part of gases produced by foaming of the foaming agent contained in the foamed rubber is sealed with the resulting resin protection membrane to form toroidally continuous cells each continuously extending substantially along a circumferential direction of the tire in the foamed rubber constituting the upper-layer rubber part.
The sheet-like member is preferable to be formed by drawing one or plural resin cords and covering such drawn resin cords with the foamed rubber through an insulation system, or by sandwiching one or plural resin cords arranged in parallel to each other between two foamed rubber sheets, or by surrounding and laminating one or plural resin cords with cord-shaped rubbers containing a foaming agent and covering with rubber through an inserter.
The fourth invention is a method of producing a pneumatic tire which comprises winding and laminating a narrow-width ribbon-shaped member of at least one resin cord covered with a foamed rubber containing a foaming agent on a green case or a shaping drum along a circumferential direction of the green case or the shaping drum to form an upper-layer rubber part constituting a tread rubber and vulcanizing, during which the resin cord is melted to form a resin protection membrane and at least a part of gases produced by foaming of the foaming agent contained in the foamed rubber is sealed with the resulting resin protection membrane to form toroidally continuous cells each continuously extending substantially along a circumferential direction of the tire in the foamed rubber constituting the upper-layer rubber part.
The ribbon-shaped member is preferable to be formed by drawing one or plural resin cords and covering such drawn resin cords with the foamed rubber through an insulation system, or by surrounding and laminating one or plural resin cords with cord-shaped rubbers containing a foaming agent and covering with rubber through an inserter.
Also, at least the upper-layer rubber part of the tread rubber is preferable to be formed by winding and laminating the ribbon-shaped member so as to overlap widthwise end portions with each other every winding while shifting in the widthwise direction of the tire.
The fifth invention is a method of producing a pneumatic tire which comprises winding and laminating a ribbon-shaped rubber sheet containing a foaming agent and resin cords on a green case or a shaping drum so as to arrange the resin cords at a given interval along a circumferential direction of the green case or the shaping drum to form an upper-layer rubber part constituting a tread rubber and vulcanizing, during which the resin cord is melted to form a resin protection membrane and at least a part of gases produced by foaming of the foaming agent contained in the foamed rubber is sealed with the resulting resin protection membrane to form toroidally continuous cells each continuously extending substantially along a circumferential direction of the tire in the foamed rubber constituting the upper-layer rubber part.
An embodiment of the first invention will be described with reference to the drawings below.
A main feature in the construction of the rubber composition 1 according to the first invention lies in the rationalization of a bubble existing state in a foamed rubber constituting the rubber composition 1, concretely the formation of continuous cells 6 in the foamed rubber, each continuously extending substantially along a particular direction 4, a longitudinal direction of the rubber composition 1 in
The foamed rubber constituting the rubber composition 1 is preferable to comprise resin cords 7 (see
a)-(d) are views illustrating a process of forming the continuous cell 6 in the foamed rubber.
a) shows a state of the foamed rubber when the heating of the foamed rubber is started in a mold (not shown). The foaming agent in the foamed rubber is gasified by the heating to start the generation of bubbles 2′.
Then, as the foamed rubber is further heated to a higher temperature (e.g. a maximum vulcanization temperature), a resin cord 7 is melted (or softened) and a viscosity thereof is made lower than a viscosity of a rubber part 3. As a result, the bubbles 2′ generated around the resulting molten resin 7′ are effectively entered into the molten resin 7′ as shown in
Thereafter, the bubbles 2′ entered into the molten resin 7′ are connected to each other in a chain in the molten resin 7′ and finally sealed with a resin protection membrane 5 made of the molten resin 7′ to form a continuous cell 6. On the other hand, the bubbles 2′ generated apart from the molten resin 7′ in the rubber part 3′ settle on their positions at a state of a spherical closed cell 2.
As a result, the spherical closed cells 2 and the continuous cells 6 reinforced with the resin protection membranes 5 can be formed in the foamed rubber constituting the rubber composition 1 of the first invention as shown in
An embodiment of the second invention will be described below.
The illustrated pneumatic tire 10 is a studless tire and comprises a tread portion 11, a pair of sidewall portions 12, a pair of bead portions 13, a carcass 15 of one ply toroidally extending between a pair of bead cores 14 each embedded in the bead portion 13 and fixed at both end portions around the bead core, and a belt 16 of two rubberized cord layers 16a, 16b arranged between a crown portion of the carcass and the tread portion 11.
Also, the tread portion 11 is made of two layers, i.e. a lower-layer rubber part 17 made of a relatively hard rubber and an upper-layer rubber part 18 applied with the same foamed rubber as the rubber composition according to the first invention.
Further, plural tread grooves, i.e. tread grooves having plural circumferential grooves 20 extending along a circumferential direction 19 of the tire and plural lateral grooves 21 intersecting therewith in
Moreover, the term “tread groove” used herein includes all grooves arranged on the tread portion 11. For example, there are mentioned slant grooves (not shown) inclined with respect to the circumferential direction 19 of the tire and the like in addition to the aforementioned circumferential grooves 20 and lateral grooves 21.
A main feature in the construction of the pneumatic tire 10 according to the second invention lies in that the upper-layer rubber part 18 is made of the rubber composition 1 shown in
a), (b) show one of the block land parts 22 constituting the tread portion worn by the running, wherein (a) is a widthwise section view and (b) is a perspective view. Moreover, the tire 10 has a toroidal form, so that the continuous cells 6 are toroidally extended substantially along the circumferential direction 19 of the tire.
As seen from these figures, drainage paths 24 extending in the circumferential direction 19 of the tire are always formed on the ground contact face of the tread portion in the tire 10 by opening the continuous cells 6 each sealed with the resin protection membrane 5 through the wearing of the tread. Furthermore, these drainage paths 24 communicate with the plural lateral grooves 21 defining the block land part and also communicate with the plural sipes 23 arranged in the same block land part, so that there can be obtained good water removing effect.
It is preferable that the foamed rubber comprises resin cords 7 continuously extending in a thready form along the circumferential direction 19 of the tire before vulcanization and a foaming agent for forming the continuous cells 6, in which the resin cord 7 is melted in the vulcanization to develop a viscosity lower than that of rubber part 3′ constituting the foamed rubber and the foaming agent has a property of foaming in the vulcanization to produce gases, and the continuous cell 6 is formed by sealing at least a part of gases produced from the foaming agent with the resin protection membrane 5 made from the resin cord 7 (see
Also, it is preferable that the resin cords 7 are arranged in a density of about one cord/1 mm for the purpose of removing water in the circumferential direction 19 of the tire. In addition, a cord diameter of the resin cord is preferable to be 10-100 μm in view of the securement of actual contact area.
Further, the continuous cells 6 are preferable to be arranged regularly or randomly at plural stages in not only the widthwise direction of the tire but also the thickness direction of the tread as shown in
The upper-layer rubber part 18 is preferable to have long cells 26 of 0.5-5 mm in length in addition to the above continuous cells 6, in which these long cells 26 are arranged so as to connect with the continuous cells 6 in a network form as shown in
Moreover, as a way for forming the long cells 26 in the upper-layer rubber part 18, it is preferable to use a method wherein long resin pieces 37 are kneaded with an uncured rubber composition 38 in an extruder 39 and a kneaded mass is extruded through a die 40 of the extruder into a given shape as shown in
The resin cord is required to have a melting point lower than a maximum vulcanization temperature of the tread rubber itself because it forms the resin protection membrane 5 sealing the continuous cell 6 therein in a tire product. The melting point is made preferably by 10° C. or less, particularly 30° C. or less than the maximum vulcanization temperature.
That is, when the difference between the melting point of the resin cord 7 and the maximum vulcanization temperature is too small, the melting of the resin cord 7 starts at a last stage of the vulcanization and the rubber part already takes a greater amount of gases therein to promote cross-linking reaction and hence an amount of gas captured in the molten resin cord becomes small and the formation of the continuous cell 6 is difficult, while when the difference between the melting point of the resin cord 7 and the maximum vulcanization temperature is too large (concretely the melting point of the resin cord is low), the resin cords 7 are melted by heat in the kneading of rubber and the fusion bonding between the molten resin cords 7′ is caused at this kneading stage and it is difficult to extend the continuous cells 6 along the circumferential direction 19 of the tire.
The term “maximum vulcanization temperature of tread rubber itself” used herein means a maximum temperature of the tread portion in the vulcanization inside a mold for a period ranging up to the cooling of the tire outside the mold.
Also, the upper-layer rubber part 18 is preferable to have a thickness corresponding to 30-70%, more preferably 40-55% of a thickness of the tread rubber. When the thickness of the upper-layer rubber part 18 is less than 30% of the thickness of the tread rubber, the foamed rubber constituting the upper-layer rubber part 18 becomes not existent at the last use stage of the tire and it is difficult to ensure the stable performances on ice-snow road in the service life of the tire, while when it exceeds 70%, the rigidity of the tread portion is apt to be lacking and there is caused a fear that the steering stability in usual running (running on dry road surface) can not be sufficiently ensured.
Furthermore, the foamed rubber constituting the upper-layer rubber part 18 is preferable that an existing ratio of all bubbles contained therein is a range of 10-40% as a weight ratio and HD is 38-58. When the existing ratio of all bubbles contained in the interior of the foamed rubber is less than 10% as a weight ratio, the drainage efficiency lowers, while when it exceeds 40%, the wear resistance and the performances on ordinary road are deteriorated. Also, when HD of the foamed rubber is less than 38, the wear resistance and the performances on ordinary road are deteriorated, while when it exceeds 58, the tire hardly follows to micro-irregularities on ice road.
In addition, the continuous cell 6 is preferable to have a sectional diameter of 10-200 μm. When the sectional diameter is less than 10 μm, the drainage efficiency is insufficient, while it exceeds 200 μm, the actual contact area lowers and hence the friction coefficient on ice lowers.
The production method of the pneumatic tire according to the third to fifth inventions will be described below.
At first, the method of forming the upper-layer rubber part 18 according to the third invention is explained. In the third invention, one or plural resin cords are arranged in parallel and covered with foamed rubber containing a foaming agent to form a sheet-like member having a given width. The term “given width” used herein means the same width as a tread rubber.
a) shows an example of a method of forming a sheet-like member 30.
This figure shows a case that one or plural resin cords 7 are drawn out from a respective bobbin(s) 31 and the drawn resin cords 7 are arranged in parallel and covered with foamed rubbers 33a, 33b extruded through two rubber extruders 32a, 32b through an insulation system, which is then passed through an inserter 34 to integrally unite the resin cords 7 and the foamed rubbers 33a, 33b with each other to thereby form a sheet-like member 30. Also, the sheet-like member 30 may be formed by covering the resin cords 7 through a single rubber extruder. The formation method of the sheet-like member 30 is not limited to the above and various formation methods can be adopted.
For example, when the resin cord is made from a frangible material or the like, as shown in
Then, the sheet-like member 30 is wound and laminated on a green case or a shaping drum, which is previously wound and laminated with a rubber sheet constituting a lower-layer rubber part 17, a shaping drum 35 in
The method of forming the upper-layer rubber part 18 in the production method of the fourth invention will be described below. In the fourth invention, the upper-layer rubber part 18 is formed by using a narrow-width ribbon-shaped member obtained by covering at least one resin cord with a foamed rubber containing a foaming agent.
In this figure, one resin cord 7 is covered with a foamed rubber extruded from a rubber extruder 32 through an insulation system and passed through an inserter 34 to cover the resin cord 7 with the foamed rubber to thereby form a ribbon-shaped member 43.
Also, the ribbon-shaped member 43 may be formed by laminating plural cord-shaped rubbers 44 containing a foaming agent around one resin cord 7 and passing through the inserter to cover the resin cord 7 with rubber as shown in
Then, the ribbon-shaped member 43 is wound and laminated on a green case or a shaping drum, which is previously wound and laminated with a rubber sheet constituting a lower-layer rubber part 17, so as to extend the resin cords 7 embedded in the ribbon-shaped member 43 along a circumferential direction of the shaping drum to thereby form the upper-layer rubber part 18.
In the fourth invention, as shown in
Such an effect can also be obtained even by using the sheet-like member according to the third invention instead of the ribbon-shaped member.
The method of forming the upper-layer rubber part 18 according to the fifth invention will be described below.
As shown in
When the upper-layer rubber part 18 formed according to any one of the third to fifth inventions is used to form a green tire and then subjected to vulcanization, the resin cords 7 in the foamed rubber constituting the upper-layer rubber part of the tire tread are melted to form the resin protection membrane 5 and at the same time at least a part of gases produced by foaming the foaming agent contained in the foamed rubber is sealed with the rein protection membrane 5, whereby there can be formed the continuous cells 6 each continuously extending substantially along the circumferential direction 19 of the tire.
Although the above is merely described with respect to the embodiment of the invention, various modifications can be conducted within the scope of the invention.
Then, the studless tire according to the second invention is prepared by the method according to the third invention applying the rubber composition according to the first invention to the upper-layer rubber part and the performances thereof are evaluated below.
Tires of Examples 1-9 are studless radial tires each having a half section in a widthwise direction of the tire shown in
Moreover, the other construction of the tire is substantially the same as in the ordinary pneumatic radial tire for a passenger car.
The tire of Conventional Example is the same as the tire of Example 1 except that the foamed rubber constituting the upper-layer rubber part has an expansion ratio of 26% as a weight ratio of rubber, HD of 48 and a thickness corresponding to 45% of a whole of a tread and the continuous cells are not formed.
(Test Method)
Each of the above tires is assembled into a rim of 6.5J×15 to form a tire-rim assembly, which is mounted onto a passenger car. Such a passenger car is run on various road surfaces (dry road surface, wet road surface, frozen road surface, snow covered road surface) to evaluate braking performances on the frozen road surface and snow covered road surface, and steering stability performances on the dry road surface and wet road surface. In this case, a tire internal pressure is 190 kPa in front and rear tires, and a load corresponds to two crewmen.
The braking performance is evaluated by measuring a stopping distance when quick braking (full braking) is applied from a speed of 20 km/h on the frozen road surface or 40 km/h on the snow covered road surface at an OFF state of ABS (anti-lock braking system).
The steering stability performance is evaluated by measuring an average time every running when the tire is run on a circuit course 10 times.
These evaluation results are also shown in Table 1. Moreover, the numerical values in Table 1 is represented by an index on the basis that the conventional example is 100, in which the larger the numerical value, the better the performance.
As seen from the evaluation results of Table 1, the example tires are equal level in the steering stability performance on the dry and wet road surfaces but are considerably excellent in the braking performances on the frozen and snow covered road surfaces as compared with the conventional tire.
According to the invention, there can be provided a rubber composition providing a large friction force even on a body having, for example, an ice face of a low friction coefficient by constituting with a foamed rubber having a rationalized foaming state, and a pneumatic tire, particularly a winter-seasoned tire such as a studless tire having improved steering stability performances such as braking performance, cornering performance and the like by applying this rubber composition to an upper-layer rubber part of a tread rubber constituting at least a ground contact face to enhance a gripping force on a frozen road surface or a snow covered road surface as well as a method of producing such a tire.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2001-303729 | Sep 2001 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP02/10070 | 9/27/2002 | WO | 00 | 3/26/2004 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO03/029342 | 4/10/2003 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 642776 | Anderson | Feb 1900 | A |
| 2143528 | Thomas | Jan 1939 | A |
| 2716435 | Herzegh | Aug 1955 | A |
| 3223572 | Holloway et al. | Dec 1965 | A |
| 3467063 | Brinkley et al. | Sep 1969 | A |
| 3607497 | Chrobak | Sep 1971 | A |
| 5387303 | Azuma | Feb 1995 | A |
| 6039826 | Okada | Mar 2000 | A |
| 6336487 | Teratani et al. | Jan 2002 | B1 |
| 6427738 | Fujino et al. | Aug 2002 | B1 |
| 6497261 | Fukushima et al. | Dec 2002 | B1 |
| 20010035255 | Sergel et al. | Nov 2001 | A1 |
| 20020084016 | Tanaka | Jul 2002 | A1 |
| Number | Date | Country |
|---|---|---|
| 0826522 | Mar 1998 | EP |
| 3-197121 | Aug 1991 | JP |
| 7-81316 | Mar 1995 | JP |
| 11-48264 | Feb 1999 | JP |
| 11-60811 | Mar 1999 | JP |
| 2000-15717 | Jan 2000 | JP |
| 2000-62043 | Feb 2000 | JP |
| 2000-108222 | Apr 2000 | JP |
| 2001-130222 | May 2001 | JP |
| WO 9734776 | Sep 1997 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 20050000614 A1 | Jan 2005 | US |
