Patent Application
20080295934
The present invention relates to a pneumatic tire capable of preventing electrostatic accumulation, more particularly to a pneumatic tire having in a sidewall portion an electrically conducting path formed by a ribbon-like electrically conductive rubber strip extending linearly in a radial direction.
In tires currently put on the market, tire-constituting components occupying 50% or more of the overall weight of a tire are made of petroleum-based materials derived from petroleum as a raw material. For example, general radial tires for passenger cars contain about 20% by weight or more of a synthetic rubber, about 20% by weight or more of a carbon black, and others, e.g., a petroleum-based oil such as aromatic oil and a synthetic fiber, based on the overall tire weight.
On the other hand, in recent years, CO2 emission regulation is tightened from the viewpoint of environmental problems. Further, as petroleum resources are limited and its supply is decreasing year by year, large increase in oil price in future is predicted. Therefore, there is a limit to the use of raw materials derived from petroleum resources. Assuming that petroleum is exhausted in future, it is important to produce tires from nonpetroleum-based materials, in other words, raw materials derived from non-petroleum resources, e.g., metals, natural rubber, inorganic fillers and/or biofillers, natural fats and oils, natural resins, natural fibers, processed products of these materials, and the like. JP-A-2003-063206 proposes an ecological tire comprising raw materials derived from non-petroleum resources in an amount of at least 75% by weight based on the total weight of the tire.
For utilizing non-petroleum resources in large quantities in tires, it is inevitable to replace a synthetic rubber and carbon black used as its reinforcing agent, which occupy a high proportion of the overall weight of tire, with natural rubber and silica which are nonpetroleum-based materials. However, since an inorganic reinforcing agent such as silica has a high electric insulation property, replacement of carbon black with silica or the like invites an increase in electric resistance of tires. Consequently, it causes a problem that static electricity is accumulated in a vehicle to cause radio disturbance such as radio noise and electrical malfunction.
A means for preventing electrostatic accumulation is known, for example, from JP-A-2007-008269 wherein, as conceptually shown in
Accordingly, it is an object of the present invention to provide a pneumatic tire capable of preventing radio disturbance, electrical malfunction and so on which are caused by electrostatic accumulation, while suppressing the amount of carbon black as small as possible to achieve utilization of nonpetroleum-based materials in high proportions.
This and other objects of the present invention will become apparent from the description hereinafter.
In accordance with the present invention, there is provided a pneumatic tire comprising at least 75% by weight, based on the overall weight of the tire, of tire-constituting components made of nonpetroleum-based materials, said tire comprising a carcass extending from a tread portion to each of bead cores in a pair of bead portions through a pair of sidewall portions, and tire rubber members including a tread rubber disposed radially outward of said carcass to provide an outer surface of said tread portion, a pair of sidewall rubbers disposed axially outward of said carcass to provide an outer surface of said sidewall portions, and a pair of clinch rubbers forming an outer surface of said bead portions,
wherein said tread rubber comprises a cap rubber which provides a ground contact surface of said tread portion, a base rubber disposed radially inward of said cap rubber, and a pair of wing rubbers disposed axially outward of said cap rubber,
a boundary surface between said cap rubber and each of said wing rubbers has an exposing end which is exposed on the outer surface of said tread portion, and the axial distance L from said exposing end to the tire equator is not less than 0.4 times a tread ground contact width and less than 0.5 times the tread ground contact width, and
wherein each of said base rubber, said cap rubber, said sidewall rubbers and a topping rubber of said carcass is formed of an insulating rubber material having a volume resistivity of at least 1×108 Ωcm, and said wing rubbers are formed of an electrically conductive rubber material having a volume resistivity of at most 1×107 Ωcm, and
said sidewall portions are provided with at least one electrically conducting path formed from a ribbon-like conductive rubber strip which is made of an electrically conductive rubber material having a volume resistivity of at most 1×107 Ω·cm and has a width Ws of 10 to 40 mm, in which a radially outer end portion of said conductive rubber strip provides an electrically conducting part which is in contact with one of said wing rubbers, and said conductive rubber strip extends linearly in a radially inward direction from said electrically conducting part to reach one of said clinch rubbers.
The term “volume resistivity” as used herein denotes a value measured by an electric resistance meter ADVANTESTER 8340A available from Advantest Co. under conditions of applied voltage 500 V, temperature 25° C. and humidity 50% using a rubber specimen of 15 cm×15 cm×2 mm (thickness).
The term “ground contact surface” or “tread ground contact surface” as used herein denotes a region in the tread surface which can come into contact with the ground when a tire is mounted on a standard rim and inflated to a normal inner pressure and this tire in the normal inner pressure state is then loaded with a normal load. Further, the maximum axial width of this ground contact surface is herein called “ground contact width” or “tread ground contact width”.
The term “rim contact region” as used herein denotes a region in the outer surface of the bead portion, which comes into contact with a rim in the normal inner pressure state.
The term “standard rim” denotes a rim defined for every tire in a standardizing system on which the tire is based and is, for example, “standard rim” in JATMA, “Design Rim” in TRA and “Measuring Rim” in ETRTO. The term “normal inner pressure” denotes an air pressure defined for every tire in the standardizing system and is, for example, the “maximum air pressure” in JATMA, the maximum value recited in the table of “Tire Load Limits at Various Cold Inflation Pressures” in TRA, and the “Inflation Pressure” in ETRTO”, provided that in case of tires for passenger cars, the “normal inner pressure” is 180 kPa. The term “normal load” denotes a load defined for every tire in the standardizing system and is, for example, the maximum load capacity in JATMA, the maximum value recited in the table of “Tire Load Limits at Various Cold Inflation Pressures” in TRA, and the “Load Capacity” in ETRTO.
The pneumatic tires of the present invention having a structure as mentioned above can reduce the electric resistance while suppressing the amount of carbon black as small as possible, and can prevent radio disturbance, electrical malfunction and so on, which are caused by electrostatic accumulation, while achieving utilization of nonpetroleum-based materials in high proportions.
An embodiment of the present invention will now be explained with reference to the accompanying drawings.
In a pneumatic tire according to the present invention, at least 75% by weight of tire-constituting components or materials based on the overall weight of the tire are made of nonpetroleum-based materials, in other words, raw materials derived from nonpetroleum resources.
As shown in
The carcass 6 comprises at least one carcass ply 6A (in this embodiment, one carcass ply) in which carcass cords are disposed at an angle of 70 to 90° with respect to the tire circumferential direction and are covered with a topping rubber. The carcass ply 6A is composed of a toroidal main portion 6a that extends from one bead core 5 to the opposing bead core 5, passing through a crown region of the tire, and turnup portions 6b that are continuous with the both ends of the main portion 6a and are turned up around the bead cores 5 from the axially inside toward the axially outside of the tire to thereby anchor the carcass ply.
For reinforcing the bead portions 4, between the carcass ply main portion 6a and each carcass ply turnup portion 6b is disposed a bead apex rubber 8 that extends radially outwardly from the bead core 5 in a tapered manner.
Each of the bead cores 5 comprises a ring body which is formed, for instance, by winding a bead wire 5w multiple times to have a predetermined cross sectional shape. It serves to sufficiently ensure engagement with a rim R and to enhance the steering stability and the bead durability.
A tread-reinforcing cord layer 10 is disposed radially outward of the carcass 6 in the tread portion 2. In this embodiment shown in
The belt 7 comprises at least two plies of belt cords which are arranged at an angle of, for instance, 15 to 40° with respect to the tire circumferential direction and covered with a topping rubber. The belt 7 shown in this embodiment comprises two belt plies 7A and 7B. The belt plies are stacked so that the belt cords in one ply cross the cords in the other belt ply, whereby the rigidity of the belt is raised to reinforce the tread portion 2 over approximately full width thereof by a hoop effect.
The band 9 comprises at least one band ply 9A of a band cord which is spirally wound at an angle of at most 50 with respect to the tire circumferential direction and covered with a topping rubber. The band 9 binds the belt 7 to enhance the steering stability, high speed durability and the like. As the band ply 9A are adoptable a pair of right and left edge band plies which are disposed to cover only axially outer edge portions of the belt 7, a full band ply which covers approximately full width of the belt 7, and a combination of them. The band 9 shown in this embodiment comprises one full band ply.
The tread-reinforcing cord layer 10 may be composed of only the belt 7 or only the band 9.
Further, for the purpose of reinforcement, a reinforcing ply (now shown) of reinforcing cords covered with a topping rubber may be additionally disposed in the bead portion 4 and/or the sidewall portion 3, as occasion demands.
Among the tire rubber members G, the clinch rubber 4G is made of a high modulus rubber which is superior in wear resistance, as well known in the art. The clinch rubber extends radially outwardly from a bead heel to form the outer surface of the bead portion 4 including at least a region RS contacting a rim flange Rf (hereinafter referred to as rim-contacting region RS). The clinch rubber 4G serves to prevent damage of the bead portion owing to slippage of the rim.
The sidewall rubber 3G is made of a relatively low modulus rubber which is superior in bending resistance. It flexibly bends to follow tire deformation to thereby prevent generation of cracks in the outer surface of the sidewall portion 3. In this embodiment shown in the drawings, a radially inner edge portion of the sidewall rubber 3G is in contact with the clinch rubber 4G to form a boundary surface Q1 which extends from a radially inner end point PL on the outer surface of the sidewall portion 3 toward the carcass 6, particularly to a point PC on the outer surface of the carcass turnup portion 6b, approximately parallel to the tire equator plane or with slightly inclining axially inwardly. Further, in the tire 1 shown in this embodiment, a radially outer edge portion of the sidewall rubber 3G is formed into a so-called TOS (tread over sidewall) structure in which the radially outer edge portion of the sidewall rubber 3G is covered with an axially outer edge portion of the tread rubber 2G. Therefore, the sidewall rubber 3G and the tread rubber 2G are in contact with each other to form a boundary surface Q2 which extends from a radially outer end point PU on the outer surface of the sidewall portion 3 to an axially outer edge of the belt 7 with inclining radially outwardly.
The tread rubber 2G comprises a cap rubber 2G1 which provides a ground contact surface 2S of the tread portion 2, a base rubber 2G2 disposed radially inward of the cap rubber 2G1, and a pair of wing rubbers 2G3 disposed axially outward of the cap rubber 2G1. An axially outer edge portion of the tread rubber 2G is bent radially inwardly so that it locates axially outward of an axially outer edge of the tread-reinforcing cord layer 10 and an axially outer edge portion of the base rubber 2G2 is located axially inward of an axially outer edge portion of the cap rubber 2G1. The tread rubber 2G can be produced using a known three layer co-extruder by which cap rubber 2G1, base rubber 2G2 and wing rubber 2G3 are co-extruded to form an integrated single body. A boundary surface Q3 between the cap rubber 2G1 and the wing rubber 2G3 has an exposing end Q3p which exposes at the outer surface of the tread portion 2. The axial distance L from the exposing end Q3p to the tire equator C is not less than 0.4 times the tread ground contact width TW and less than 0.5 times the tread ground contact width TW. That is to say, the wing rubber 2G3 extends axially inwardly beyond a tread ground contact edge Te so that an axially inner edge portion of the wing rubber is located in a ground contact region. A part of the wing rubber 2G3 can contact the ground when running. If the distance L is less than 0.4 times the ground contact width TW (L/TW<0.4), uneven wear occurs between the cap rubber 2G1 and the wing rubber 2G3 to deteriorate the appearance. If the distance L is not less than 0.5 times the ground contact width TW, the wing rubber 2G3 does not surely contact the ground. Therefore, preferably the distance L is at least 0.42 times the ground contact width TW and at most 0.46 times the ground contact width TW.
In this embodiment, the wing rubber 2G3 is in the form of a sheet having a thickness of 0.5 to 2.0 mm. Therefore, its rubber volume is kept low, but the wing rubber 2G3 can surely contact the ground even in the case that the tread rubber 2G is worn away, since the radially outer edge portion of the wing rubber is located axially inward of the tread ground contact edge Te.
Herein, carcass cords, bead wire, belt cords, band cords, reinforcing cords and so on may be generically called “tire cords”.
The tire rubber members G include, for instance, besides the above-mentioned tread rubber 2G, sidewall rubber 3G and clinch rubber 4G, an inner liner rubber (not shown) which forms a tire cavity surface, the bead apex rubber 8, and topping rubbers used for respective plies.
In the present invention, at least 75% by weight, preferably at least 85% by weight, more preferably at least 95% by weight, of all tire-constituting components including the tire cords and the tire rubber members based on the overall weight of the tire are formed from nonpetroleum-based materials. The term “nonpetroleum-based materials” as used herein means materials derived from raw materials other than petroleum and encompasses, for instance, metals, natural rubber, inorganic fillers and/or biofillers, natural fats and oils, natural resins, natural waxes, natural fibers, processed products of these materials, and the like.
Specifically, in this embodiment shown in the drawings, cords made of nonpetroleum-based materials are used for a part or all of the tire cords. For carcass cords, band cords, reinforcing cords and so on of the tire cords have been conventionally used synthetic fiber cords made of raw materials derived from petroleum resources, e.g., nylon polyester and aromatic polyamide. In the present invention, a part or all of such synthetic fiber cords are replaced with cords made of nonpetroleum-based materials. As the cords made of nonpetroleum-based materials can be used metal cords made of metals and natural fiber cords made of natural fibers or processed products thereof. Natural fiber cords are preferred from the viewpoint of suppressing increase of fuel consumption owing to weight increase.
As the natural fiber cords can be suitably used cords of regenerated cellulose fibers such as rayon, cuprammonium rayon (cupro) and acetate fibers, and cords of refined cellulose fibers such as lyocell (available under the trade mark “Tencel” from Lenzing AG). These regenerated cellulose fibers and refined cellulose fibers have a high breaking strength comparable to nylon fibers and polyester fibers and, therefore, are suitable for use as a tire cord. In particular, the refined cellulose fibers have a feature of having a high modulus, since the degree of crystallization thereof is high as compared with the regenerated cellulose fibers and the orientation of crystal portion and non-crystal portion is high. Furthermore, because of having a high degree of crystallization and a high orientation of crystal and non-crystal portions, the refined cellulose fibers have the feature that moisture is hard to enter between cellulose molecular chains and therefore the stability of strength and elongation to moisture is high, whereas rayon tends to cause deterioration of strength owing to moisture. Therefore, the stability of strength and elongation to moisture can be enhanced by using the refined cellulose fiber cords as a carcass cord and/or a band cord. Thus, such a use of refined cellulose fiber cords is not mere replacement with petroleum-based fiber cords, but produces an effect of improving the high speed durability and the high speed steering stability as compared with conventional tires using nylon cords, polyester cords and so on. In case of heavy duty tires, it is preferable to use metal cords, e.g., steel cords, as carcass cords or reinforcing cords in the same manner as conventional heavy duty tires.
Metal cords and metal wires have been conventionally used as belt cords or bead wires. In the present invention, too, the metal cords or wires are applied to the belt cords and bead wires in the same manner as conventional tires. From the viewpoint of preventing the fuel cost from increasing owing to increase in weight, it is preferable to use metal cords and wires in an amount of at most 20% by weight based on the overall weight of the tire.
The tire rubber members G are produced from various rubber compositions containing a rubber component and additives known for use in tires. In the present invention, a part or all of the rubber component and a part or all of the additives are constituted by nonpetroleum-based materials. It is known to use, as the rubber component, a blend of a nonpetroleum-based material, natural rubber, with a synthetic rubber prepared from a raw material derived from a petroleum resource, such as styrene-butadiene rubber (SBR), butadiene rubber (BR) or butyl rubber (IIR). For example, from the viewpoints of tear resistance and low rolling resistance, it is known to use a blend of natural rubber and styrene-butadiene rubber in the tread rubber 2G, the bead apex rubber 8 and the topping rubbers for respective plies. Also, from the viewpoints of tear resistance and flex cracking resistance, it is known to use a blend of natural rubber and butadiene rubber in the sidewall rubber 3G and the clinch rubber 4G. Further, from the viewpoints of adhesion property and air impermeability, it is known to use a blend of natural rubber and butyl rubber in the inner liner rubber. In the present invention, in such rubber blends, a part or all of the synthetic rubber is replaced with a rubber made of a nonpetroleum-based material.
Natural rubber (including modified natural rubbers) is used as a rubber made of a nonpetroleum-based material. A typical example of the modified natural rubber is an epoxidized natural rubber. The epoxidized natural rubber tends to have superior performances such as grip performance, low rolling resistance and flex cracking resistance. Accordingly, a blend of natural rubber and epoxidized natural rubber can be suitably used in various tire rubber members which require different properties from each other, by suitably changing the blending ratio.
Examples of the additives to be incorporated into the tire rubber members G are, for instance, a reinforcing agent, a softener, a vulcanizing agent, a vulcanization accelerator, an antioxidant, a tackifier, and the like. Of these additives, reinforcing agent, softener and vulcanizing agent are added to a rubber component as essential components, and other additives are used as occasion demands.
As a reinforcing agent has been conventionally used a carbon black prepared using a petroleum resource as a raw material, from the viewpoint of reinforcing effect. In conventional tires, the amount of carbon black is about 20% by weight or more based on the overall weight of a tire. In the present invention, a part or all of the carbon black is replaced with a nonpetroleum-based reinforcing agent, i.e., an inorganic filler and/or a biofiller. Examples of the inorganic filler are, for instance, silica, sericite, calcium carbonate, clay, alumina, talc, magnesium carbonate, aluminum hydroxide, magnesium hydroxide, magnesium oxide, titanium oxide, and the like. Examples of the biofiller are, for instance, plant-derived polysaccharides such as starch and cellulose, and animal-derived polysaccharides such as chitin and chitosan. Of these, silica is preferred from the viewpoint of ensuring the effect of reinforcing a rubber.
As a softener have been conventionally used petroleum-based oils such as paraffinic oils, aromatic oils and naphthenic oils which are derived from petroleum resources. In conventional tires, the petroleum-based oils are generally used in an amount of about 8% by weight based on the overall weight of a tire. In the present invention, a part or all of the petroleum-based oils are replaced by a nonpetroleum-based softener, i.e., natural oils and fats. Vegetable oils and fats can be used as the natural oils and fats. Examples of the vegetable oils and fats are, for instance, castor oil, cotton seed oil, linseed oil, rape seed oil, soybean oil, palm oil, coconut oil, peanut oil, rosin, pine oil, pine tar, tall oil, corn oil, rice oil, safflower oil, sesame oil, olive oil, sunflower oil, palm kernel oil, camellia oil, jojoba oil, macadamia nut oil, safflower oil and tung oil. Of these, vegetable oils and fats having a low degree of unsaturation are preferred, e.g., semi-drying oils having an iodine number of 100 to 130, non-drying oils having an iodine number of at most 100, and solid fats. The “iodine number” denotes the number of grams of iodine absorbed by 100 g of sample. If the iodine number of vegetable oils and fats is more than 130, there is a tendency that the loss factor (tan δ) increases and the hardness decreases, thus causing increase of rolling resistance and decrease of steering stability.
Other additives such as vulcanizing agent, vulcanization accelerator, antioxidant and tackifier have a great influence on rubber properties, although the amounts thereof are very small as compared with the reinforcing agent and the softener. Therefore, as these additives, conventionally used ones are preferably used in the present invention.
In the tires according to this embodiment shown in the drawings, at least the cap rubber 2G1, the base rubber 2G2, the sidewall rubber 3G and the topping rubber of carcass 6 are formed of insulating rubber materials which contains an organic filler such as silica as a reinforcing agent to have a volume resistivity of at least 1×108 Ω·cm. The reason is that these rubbers occupy a large volume in a tire and have a large degree of contribution to ecology. Preferably, rubber members other than the wing rubber 2G3 and a ribbon-like electrically conductive rubber strip 21 (shown in
In contrast, the wing rubber 2G3 and the electrically conductive rubber strip 21 are formed of electrically conductive rubber materials having a volume resistivity of at most 1×107 Ω·cm for the purpose of decreasing the electric resistance. In the conductive rubber materials, the volume resistivity is decreased usually by using a large amount of carbon black as a reinforcing agent, but it may be used in combination with an ionic conductive material such as a lithium salt or a metal material such as nickel in order to decrease the volume resistivity within the above-mentioned range.
In the tires according to the present embodiment, at least one electrically conducting path 20 (in the present embodiment, one conducting path 20) made of an electrically conductive rubber strip 21 is formed in the sidewall portion 3, as shown in
The electrically conductive rubber strip 21 is a ribbon-like material having a width Ws (shown in
In the embodiment shown in the drawings, the radially outer end portion of the conductive rubber strip 21 is disposed at the boundary surface Q2 between the sidewall rubber 3G and the tread rubber 2G to form a nip-holding portion 21a which is sandwiched between the sidewall rubber 3G and the tread rubber 2G and held thereby. The conducting part 21A which is in contact with the wing rubber 2G3 is located at a part of the nip-holding portion 21a. The conductive rubber strip 21 (conducting path 20) has a main portion 21b which is continuous with the nip-holding portion 21a and extends radially inwardly while contacting the outer surfaces of the sidewall rubber 3G and the clinch rubber 4G. A lower end portion 21b1 of the main portion 21b can terminate to expose at the rim-contacting region RS of the clinch rubber 4G. In this case, an insulating rubber material can be used for the clinch rubber 4G.
Since the conductive rubber strip 21 (conducting path 20) electrically connects the wing rubber 2G3 and the rim R at a minimal distance, it exhibits an excellent conducting performance and accordingly can sufficiently lower the electric resistance of a tire in spite of a single narrow-width ribbon-like material having a width Ws of 10 mm or less. The outer end portion (nip-holding portion 21a) of the rubber strip 21 (conducting path 20) is sandwiched between the tread rubber 2G and the sidewall rubber 3G so as to contact the wing rubber 2G3 at the conducting part 21A. Therefore, stable electric conduction with the wing rubber 2G3 is secured. Further, since the radially inner end portion of the rubber strip 21 which is located at the rim-contacting region RS is always in contact with the rim R with pressure, stable electric conduction with the rim R is also secured although the strip 21 is a single narrow-width ribbon-like material.
If the width Ws of the rubber strip 21 is less than 10 mm, the conducting performance tends to be insufficient for sufficiently lower the electric resistance. If the width Ws is more than 40 mm, the volume of the rubber strip 21 and the amount of carbon black incorporated therein unnecessarily increase. From the same viewpoints, it is preferable that the thickness of the electrically conductive rubber strip 21 is from 0.5 to 2.0 mm.
Since the conductive rubber strip 21 (conductive path 20) has a narrow width, it does not exert a bad influence on the tire performances including uniformity. Therefore, unbalanced arrangement of the conducting path 20 is possible. For example, the conducting path 20 may be formed in only one of a pair of sidewall portions 3 and/or only single conducting path 20 may be formed.
As shown in
The clinch rubber 4G may be formed of an electrically conductive rubber material, although it is undesirable from the viewpoint of increasing the proportion of nonpetroleum-based materials in tires. In this case, as shown in
In a green tire forming process, the sidewall rubber 3G is formed, for example, by winding a raw rubber sheet for sidewall rubber around a tire forming drum in the circumferential direction of tire. Therefore, as shown in
In
The conductive rubber strip 21 (conducting path 20) is composed of a nip-holding portion 21a which is located at the boundary surface Q2 and sandwiched between the sidewall rubber 3G and the tread rubber 2G (wing rubber 2G3), and a main portion 21b which is continuous with the nip-holding portion 21a and extends radially inwardly through a location between the carcass 6 and the sidewall rubber 3G and a location between the carcass 6 and the clinch rubber 4G. In this example, a lower end portion 21b1 of the main portion 21b is exposed at a bead bottom 4S to achieve electric conduction with the rim R, as shown in
While a preferable embodiment of the present invention has been described with reference to the drawings, it goes without saying that the present invention is not limited to only such an embodiment and various changes and modifications may be made. The present invention is more specifically described and explained by means of the following examples and comparative examples. It is to be understood that the present invention is not limited to these examples.
Pneumatic tires (size: 215/45ZR17) having a base structure shown in
In both the Examples and the Comparative Examples, rubber members other than a wing rubber and a conductive rubber strip for electric conduction were formed of an insulating rubber member containing 30 parts by weight of silica per 100 parts by weight of a rubber component (natural rubber) and having a volume resistivity of 1×108 Ω·cm or more. The wing rubber and the conductive rubber strip were formed of an electrically conductive rubber member containing 30 parts by weight of carbon black per 100 parts by weight of a rubber component (natural rubber) and having a volume resistivity of 8.0×105 Ωcm.
The results are shown in Table 1.
The electric resistance of a tire-rim assembly was measured according to a JATMA standard by using a measuring apparatus having, as shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-142216 | May 2007 | JP | national |
