Patent Application
20180244113
The present invention relates to a run flat tire capable of running even in a punctured state, and a manufacturing method thereof.
Conventionally, there has been known a run flat tire in which a side reinforcing rubber layer having a substantially crescent cross-sectional shape is disposed inside a carcass at a side wall portion (see Japanese unexamined Patent Application Publication No. 2010-6327: Patent Literature 1, for example).
In Patent Literature 1, the side reinforcing rubber layer includes a first rubber portion disposed closest to the tread portion, and a second rubber portion connected with the first rubber portion, extending toward a bead portion, and harder than the first rubber portion.
The run flat tire provided with the side reinforcing rubber layer generally has a high longitudinal blade constant, therefore, ride comfort is deteriorated when compared with a normal pneumatic tire. Even in the run flat tire disclosed in Patent Literature 1, the second rubber portion which is harder than the first rubber portion extends to the vicinity of an outer end of a belt layer, which is a center of ground contacting area during run-flat running, therefore, it is possible that the ride comfort is deteriorated. Further, rigidity difference is likely to be generated in the vicinity of the outer end of the belt layer, therefore, it is possible that it may affect durability due to stress concentration.
The present invention was made in view of the above, and a primary object thereof is to provide a run flat tire having the ride comfort and the durability during run flat running improved in a good balance.
In one aspect of the present invention, a run flat tire comprises a carcass extending between a pair of bead cores of bead portions via a tread portion and a pair of sidewall portions, a belt layer formed by a plurality of belt plies arranged outside the carcass in a tire radial direction within the tread portion, and a pair of side reinforcing rubber layers each arranged inside the carcass in each of the sidewall portions and having a substantially crescent cross-sectional shape, wherein each of the side reinforcing rubber layers comprises a first rubber portion arranged on a side of the tread portion and a second rubber portion connected with the first rubber portion so as to have a boundary surface therebetween, extending from the boundary surface toward the adjacent bead portion, and having a modulus larger than the first rubber portion and constant between the boundary surface and the adjacent bead portion, in a tire meridian section passing through a tire rotational axis and in each of the side reinforcing rubber layers, a first point where the boundary surface intersects with an outer surface of the side reinforcing rubber layer in a tire axial direction is arranged on a side of the adjacent bead portion in the tire radial direction of a second point of the outer surface which is a closest point to an outer end of the belt layer in the tire axial direction, a third point where the boundary surface intersects with an axially inner surface of the side reinforcing rubber layer is arranged on a side of the adjacent bead portion in the tire radial direction of the first point and a fourth point which is a closest point of the axially inner surface to the outer end, and a distance L1 along the outer surface between an axially inner end of the first rubber portion and the second point is larger than a distance L2 along the outer surface between the second point and the first point.
In another aspect of the invention, it is preferred that a distance L3 along the inner surface between the axially inner end of the first rubber portion and the fourth point is larger than a distance L4 along the inner surface between the fourth point and the third point.
In another aspect of the invention, it is preferred that a ratio L5/L6 of a distance L5 between the outer end of the belt layer and the second point to a distance L6 between the second point and the fourth point is in a range of from 0.45 to 1.00.
In another aspect of the invention, it is preferred that a ratio L2/L7 of the distance L2 to a distance L7 along an inner circumferential surface of the belt layer between a tire equator and the outer end is in a range of from 0.08 to 0.2.
In another aspect of the invention, it is preferred that a ratio L4/L7 of the distance L4 to the distance L7 is in a range of from 0.13 to 0.3.
In another aspect of the invention, it is preferred that in a standard state in which the run flat tire is mounted on a standard rim, inflated to a standard pressure, and loaded with no tire load, a distance L8 in the tire radial direction between a bead base line and the first point is in a range of from 75% to 80% of a tire section height.
In another aspect of the invention, it is preferred that in the standard state, a distance L9 in the tire radial direction between the bead base line and the third point is in a range of from 70% to 75% of the tire section height.
In another aspect of the invention, it is preferred that a ratio W1/W2 of a thickness W1 of the first rubber portion at the second point to a maximum thickness W2 of the second rubber portion in the tire radial direction is in a range of from 0.55 to 0.65.
In another aspect of the invention, it is preferred that the first rubber portion is made of rubber having a 2% modulus at 70 degrees celsius in a range of from 4 to 10 MPa.
In another aspect of the invention, it is preferred that the second rubber portion is made of rubber having a 2% modulus at 70 degrees celsius in a range of from 10 to 16 MPa.
In another aspect of the invention, it is preferred that each of the bead portions is provided with an outer bead apex rubbers having a larger modulus than the second rubber portion and arranged axially outside the carcass so as to extend radially outwardly from the bead core in a tapered manner.
In another aspect of the invention, a method for manufacturing the run flat tire includes a green tire forming step of forming a green tire by using a rigid core having a tire-forming surface on an outer surface thereof and sequentially applying unvulcanized tire components on the tire-forming surface, and a vulcanizing step of introducing the green tire together with the rigid core into a vulcanizing mold and vulcanization molding the green tire, wherein the green tire forming step includes a step of winding a first belt-like rubber for forming the first rubber portion outside the tire-forming surface, a step of winding a second belt-like rubber for forming the second rubber portion radially outside the first belt-like rubber, and a step of applying a carcass ply for forming the carcass on outside of the first belt-like rubber and the second belt-like rubber.
An embodiment of the present invention will now be described in conjunction with accompanying drawings.
The “standard state is a state in which a tire is mounted on a standard rim, inflated to a standard pressure, and loaded with no tire load. Unless otherwise noted, dimensions and the like of various parts of the tire are values measured of the tire in the standard state.
The “standard rim” is a wheel rim specified for the concerned tire by a standard included in a standardization system on which the tire is based, for example, the “normal wheel rim” in JATMA, “Design Rim” in TRA, and “Measuring Rim” in ETRTO.
The “standard pressure” is air pressure specified for the concerned tire by a standard included in a standardization system on which the tire is based, for example, the “maximum air pressure” in JATMA, maximum value listed in the “TIRE LOAD LIMITS AT VARIOUS COLD INFLATION PRESSURES” table in TRA, and “INFLATION PRESSURE” in ETRTO.
The run flat tire 1 in this embodiment includes a carcass 6 extending between a pair of bead cores 5 of bead portions 4 via a tread portion 2 and sidewall portions 3, a belt layer 7, and side reinforcing rubber layers 10.
The carcass 6 includes at least one carcass ply 6A, and is formed so as to extend between a pair of the bead portions 4 in a toroidal shape.
The belt layer 7 is arranged outside the carcass 6 in a tire radial direction and inside the tread portion 2. The belt layer 7 in this embodiment is formed by the radially inner belt ply 7A and a radially outer belt ply 7B. Each of the belt plies 7A and 7B is formed by belt cords made of steel arranged at an angle in about a range of from 10 to 35 degrees with respect to a tire equator (C), for example. The belt plies 7A and 7B are overlapped so that the belt cords cross each other, and strongly tighten the carcass 6 to increase rigidity of the tread portion 2. Note that the inner belt ply 7A is wider than the outer belt ply 7B, therefore, outer edges (7e) of the belt layer 7 is determined by the inner belt ply 7A. Further, in addition to steel material, highly elastic organic fiber materials such as aramid and rayon can be used for the belt cords as required.
The bead cores 5 are disposed in a pair of bead portions 4. Each of the bead cores 5 in this embodiment includes an inner core (5i) disposed inside the carcass ply 6A in a tire axial direction and an outer core (5o) disposed outside the carcass ply 6B in the tire axial direction.
In this embodiment, a band layer 8 is arranged outside the belt layer 7 in the tire radial direction. The band layer 8 is formed of at least one band ply in which organic fiber cords are arranged at a small angle so as to be not greater than 10 degrees, for example, with respect to a tire circumferential direction. The band ply may be either a jointless band formed by spirally winding a band cord or a ribbon-shaped belt-like ply, or spliced plies.
Each of the side reinforcing rubber layers 10 is arranged inside the carcass 6 in each of the sidewall portions 3 and is formed to have a substantially crescent cross-sectional shape. Each of the side reinforcing rubber layers 10 is arranged so as to extend from one of shoulder portions of the tread portion 2 to one of the bead portions 4 via one of the sidewall portions 3 adjacent thereto. The side reinforcing rubber layers 10 support the load when the tire is punctured and suppress deflection of the tire.
Note that an inner liner layer 9 made of air impermeable rubber is formed inside the carcass 6 and the side reinforcing rubber layers 10, that is, formed on a tire inner cavity surface. By suppressing the deflection of the tire by the side reinforcing rubber layers 10, damage of the inner liner layer 9 due to friction is suppressed, therefore, run flat running becomes possible.
Each of the side reinforcing rubber layers 10 includes a first rubber portion 11 disposed on a side of the tread portion 2, a second rubber portion 12 disposed on a side of the bead portion 4, and a boundary surface 13 between the first rubber portion 11 and the second rubber portion 12. The first rubber portion 11 is formed by a single rubber layer and has a constant modulus from an inner end P5 in the tire axial direction to the boundary surface 13. The second rubber portion 12 is connected with the first rubber portion 11 at the boundary surface 13 and extends toward the bead portion 4. The second rubber portion 12 is made of rubber having a higher modulus than that of the first rubber portion 11. The second rubber portion 12 is formed by a single rubber layer and has a constant modulus from the boundary surface 13 to the bead portions 4 (an inner end in the tire radial direction). Thereby, the configuration and manufacturing process of the run flat tire 1 is simplified, therefore, cost reduction is achieved.
“Modulus” in this specification is a modulus at 2% elongation measured at 70 degrees celsius according to the test method described in Japanese Industrial standard JIS K6251 “Tensile Test Method of vulcanized Rubber”. The ride comfort is improved by the first rubber portion 11 having a small modulus disposed on the side of the tread portion 2. Further, deflection of the tire when the inner pressure thereof is decreased is suppressed by the second rubber portion 12 having a large modulus disposed on the side of the bead portion 4, therefore, run flat durability is improved.
Further, a third point P3 where the boundary surface 13 intersects with an inner surface (10b) of the side reinforcing rubber layers 10 in the tire axial direction is arranged on a side of the bead portions 4 in the tire radial direction of the first point P1. Furthermore, the third point P3 is arranged on a side of the bead portion 4 in the tire radial direction of a fourth point P4 which is the closest point of the inner surface (10b) to the outer end (7e). Thereby, the area of the first rubber portion 11 is sufficiently secured, therefore, it is possible that the ride comfort is easily improved.
Further, a distance L1 along the outer surface (10a) of the side reinforcing rubber layers 10 between the inner end P5 in the tire axial direction of the first rubber portion 11 and the second point P2 is larger than a distance L2 along the outer surface (10a) of the side reinforcing rubber layers 10 between the second point P2 and the first point P1. Thereby, a region from a region axially inside the ground contacting area (A) to the sidewall portion 3 is gradually reinforced by the first rubber portion 11 and the second rubber portion 12, therefore, durability during run flat running is improved. Further, by the first rubber portion 11 having a smaller modulus than the second rubber portion 12, buckling deformation occurring in the tread portion 2 during run flat running is suppressed, therefore, the durability is improved.
A distance L3 along the inner surface (10b) between the inner end P5 and the fourth point P4 is larger than a distance L4 along the inner surface (10b) between the fourth point P4 and the third point P3. Thereby, a region from a region axially inside the ground contacting area (A) of the tread portion 2 to the sidewall portion 3 is gradually reinforced by the first rubber portion 11 and the second rubber portion 12, therefore, the durability during run flat running is improved.
The first point P1 in this embodiment is arranged axially outside an outer end (8e) of the band layer 8. Thereby, the rigidity of the side reinforcing rubber layer 10 in the vicinity of the outer end (8e) of the band layer 8 in the tire axial direction is moderated, therefore, it is possible that the ride comfort is easily improved.
It is preferred that a ratio L2/L7 of the distance L2 and a distance L7 (see
It is preferred that a ratio L4/L7 of the distance L4 and the distance L7 (see
It is preferred that a distance L9 in the tire radial direction between the bead base line BL and the third point P3 in the standard state is in a range of from 70% to 75% of the tire section height (H). If the distance L9 is less than 70% of the tire section height (H), the area of the first rubber portion 11 having a low modulus expands toward the bead portion 4, therefore, it is possible that the durability during run flat running is affected. On the other hand, if the distance L9 is larger than 75% of the tire section height (H), the area of the second rubber portion 12 having a high modulus expands toward the belt layer 7, therefore, it is possible that the ride comfort is affected.
It is preferred that a ratio W1/W2 of a thickness W1 of the first rubber portion 11 at the second point P2 (that is, the distance L6) and a maximum thickness W2 of the second rubber portion 12 in the tire axial direction is in a range of from 0.55 to 0.65. If the ratio W1/W2 is less than 0.55, reinforcing effect of the side reinforcing rubber layer 10 at the center of the ground contacting area (A) of the tread portion 2 during run flat running is decreased, therefore, it is possible that the durability is affected. Or, the longitudinal blade constant of the run flat tire 1 inflated to the standard pressure is increased, therefore, it is possible that the ride comfort is affected. On the other hand, if the ratio W1/W2 is larger than 0.65, more buckling deformation occurs in the tread portion 2 during run flat running, therefore, it is possible that the durability is affected. Or, the deflection of the sidewall portions 3 is increased during run flat running, therefore, it is possible that the durability is affected.
In the present embodiment, a point P6 at which the maximum thickness W2 in the tire axial direction of the second rubber portion 12 is measured is located on a side of the bead portion 4 in the tire radial direction of the maximum width portion of the carcass 6. Thereby, together with the side reinforcing rubber layers 10 being composed of two layers, flexural rigidity of the sidewall portion 3 gradually increases from the shoulder portion to the bead portion 4, therefore, the ride comfort and the durability during run flat running are improved in a good balance at a high level.
It is preferred that a 2% modulus M1 of the rubber constituting the first rubber portion 11 at 70 degrees celsius is in a range of from 4 to 10 MPa. If the modulus M1 is less than 4 MPa, the deflection of the tire during run flat running is increased, therefore, it is possible that the durability is affected. If the modulus M1 is larger than 10 MPa, it is possible that the ride comfort is affected.
It is preferred that a 2% modulus M2 of the rubber constituting the second rubber portion 12 at 70 degrees celsius is in a range of from 10 to 16 MPa. If the modulus M2 is less than 10 MPa, the deflection of the tire during run flat running is increased, therefore, it is possible that the durability is affected. If the modulus M2 is larger than 16 MPa, it is possible that the ride comfort is affected.
As shown in
In the green tire forming step S1, a rigid core having a tire-forming surface on an outer surface thereof is used. For the rigid core in this embodiment, a known rigid core can be used. A green tire is formed by sequentially applying unvulcanized tire components onto the tire-forming surface of the rigid core.
In step S11, an inner liner rubber for forming the inner liner layer 9 is wound on the tire-forming surface of the rigid core. In step S12, a first belt-like rubber for forming the first rubber portion 11 is wound around the outer side of the inner liner rubber.
In step S13, a second belt-like rubber for forming the second rubber portion 12 is wound axially outside the inner liner rubber and radially inside the first belt-like rubber. In steps S12 and S13, the first belt-like rubber and the second belt-like rubber are wound so that the first rubber portion 11 and the second rubber portion 12 have desired dimensions. In step S14, an inner wire for forming the inner core (5i) is wound radially inside the first belt-like rubber.
In step S15, the carcass ply 6A for forming the carcass 6 is applied on the outside of the first belt-like rubber and the second belt-like rubber. In step S16, an outer wire for forming the outer core (5o) is wound axially outside the carcass ply 6A. In step S17, belt-like rubbers for forming the outer bead apex rubbers 14, sidewall rubbers and the like are wound axially outside the carcass ply 6A.
In step S18, the belt plies 7A and 7B are applied on the radially outside of the carcass ply, and in step S19, the band ply for forming the band layer 8 and belt-like rubber for forming tread rubber are wound radially outside the belt plies 7A and 7B.
In the vulcanizing step S2, the green tire is introduced into a vulcanizing mold together with the rigid core, and then vulcanization molding is performed. According to this manufacturing method, the green tire is not inflated by a bladder and the like from the green tire forming step S1 to the vulcanizing step S2, therefore, dimensions of the first rubber portion 11 and the second rubber portion 12 of the side reinforcing rubber layers 10 are stabilized, thereby, it is possible that good accuracy is obtained.
While detailed description has been made of the run flat tire and the manufacturing method thereof as embodiments of the present invention, the present invention can be embodied in various forms without being limited to the illustrated embodiment.
Run flat tires of size 245/45R18 having the basic structure shown in
Cord of carcass ply: aramid fiber
Cord of belt ply: steel
Cord of band ply: aramid fiber
The test tires were mounted on all wheels of a European sedan car having rims of 18×8J and inflated to 230 kPa. A test driver drove the test car on a dry asphalt road of a test course with the driver being the only member in the test car, and the ride comfort relating to movement above suspension, hardness on shaking, rigid impression, and the like during the test drive was evaluated by the driver's feeling. The results are indicated by an evaluation point based on Example 1 being 100, wherein a larger numerical value is better.
For each of the test tires, running distance was measured by using a run flat durability drum under the conditions specified by ISO. The results are indicated by an index based on Example 1 being 100, wherein a larger numerical value is better.
As is clear from Table 1, it was confirmed that the ride comfort and the run flat durability of the run flat tire as Example 1 were significantly improved in a good balance as compared with References 1 to 3.
Further, run flat tires of size 245/45R18 having the basic structure shown in
The test car was driven on a dry road surface of a circuit track of a test course, and the characteristics related to steering response, responsiveness, and lateral grip were evaluated by the driver's feeling. The results are indicated by an evaluation point based on Example 4 being 100, wherein the larger the numerical value, the better the handling performance is.
Each of the test tires was mounted on a rim of 18×8J and inflated to 230 kPa, and then run on a drum testing machine at a speed of 180 km/h and running time until damage to the belt layer occurred was measured. The results are indicated by an index based on Example 4 being 100, wherein the larger the numerical value, the better the high-speed durability is.
Furthermore, run flat tires of size 245/45R18 having the basic structure shown in
Furthermore, run flat tires of size 245/45R18 having the basic structure shown in
Furthermore, run flat tires of size 245/45R18 having the basic structure shown in
Furthermore, run flat tires of size 245/45R18 having the basic structure shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| 2017-037068 | Feb 2017 | JP | national |
| 2018-005100 | Jan 2018 | JP | national |
