The present invention relates to a tire wheel assembly used for a pneumatic tire enabling limited driving in a damaged or deflated state (hereinafter referred to as a “run flat tire”), more specifically relates to an improved tire wheel assembly capable of improving the bondability of the contact parts of a ring-shaped metal shell and rubbery elastic members of a run flat support member comprised of a ring-shaped metal shell and rubbery elastic members provided at the inside cavity of the tire/rim and the rubbery elastic members, without using an adhesive.
There is a need for a pneumatic run flat tire having an emergency driving capable of driving for a certain distance, even if the tire rapidly drops in the inside pressure due to its being punctured or bursting during driving of the automobile etc. Numerous proposals have been made to meet such a need. As such proposals, for example, Japanese Patent Publication (A) No. 10-297226 and Japanese Patent Publication (A1) No. 2001-519279 propose technology attaching a run flat support member (i.e., mandrel) on the rim at the inside cavity of the pneumatic tire and using this to support a punctured or otherwise damaged pneumatic tire to enable run flat driving.
The run flat support member has a ring-shaped member having the outer circumference as a support surface, has elastic rings attached to the two legs thereof, and has the support member supported on the rim through the elastic rings. Technology using the run flat support member enables use of the wheels/rims of conventional general pneumatic tires as they are, without making any special modifications to the wheels/rims, and therefore, has the advantage of enabling use of conventional pneumatic tire production, processing, and mounting facilities as they are.
Contrary to the above, as a typical method, there is also technology reinforcing the sidewalls to enable run flat driving, but this has the problem that sufficient performance cannot be exhibited in tire sizes with high tire cross-sectional heights. As technology providing a mandrel in the inside cavity of the tire as explained above, there is technology making the mandrel solid, but this has the problem that since the mandrel has no flexibility, it is difficult to mount. Further, there are proposals using special rim structures or special tire structures, but this has the problem that neither the tires nor the wheels have general applicability, and therefore an excessive burden is placed on the user.
However, technology using a run flat support member is superior in terms of general applicability and ease of mounting, but the bonding strength at the contact surfaces between the elastic rings and the ring-shaped member has a large effect on the durability of the run flat support member and greatly influences the durability. Therefore, to improve the durability of the run flat support member in the tire wheel assembly mounting a run flat support member and increase the run flat driving distance, it is necessary to improve the bondability between the back surface of the metal shell and the rubber elastic members of the support member and the durability thereof.
Various proposals have been made to increase the bonding strength between the metal shell and the rubbery elastic members from this viewpoint. For example, Japanese Patent Publication (A) No. 2004-074857 proposes bonding by an adhesive, Japanese Patent Publication (A) No. 2004-074855 bonding by electrolytic polymerization treatment, Japanese Patent Publication (A) No. 2004-074854 bonding by electrolytic polymerization and formulation of peroxide, and Japanese Patent Publication (A) No. 2004-106692 direct bonding by a high sulfur content and formulation of a resol-type alkyl phenol resin. In the technology of Japanese Patent Publication (A) No. 2004-106692, to improve the bonding between the ring-shaped metal shell (steel) and the rubber, the past practice of using an indirect binder or applying special surface treatment was replaced by making the rubber compound side a high sulfur formulation and resin formulation system so as to make the rubbery elastic members and the metal (steel) directly bondable. Further, as a method for making the metal and the rubbery elastic members directly bond, the techniques of formulating acetyl acetonate, formulating silica, or formulating iron naphthenate were developed. However, these rubber/metal directly bondable compounds suffer from the problems that inclusion of special compounding agents led to an increase in costs, the rubber stuck to the mold surface at the time of vulcanization molding, etc. This obstructed commercialization.
Accordingly, the objects of the present invention are to improve the direct bondability of the ring-shaped metal shell and the rubbery elastic members forming the run flat support member of the run flat tire wheel assembly and to improve the durability and the run flat driving capability of the run flat support member.
In accordance with the present invention, there is provided a run flat tire wheel assembly comprising a run flat support member formed by a ring-shaped metal shell and rubbery elastic members in an inside cavity of a tire/rim, wherein the rubbery elastic members are comprised of at least two types of rubber differing at least at the vicinity of the bonded parts with the ring-shaped metal shell and at the other locations and wherein the vicinity of the bonded parts with the ring-shaped metal shell is formed with a directly bondable rubber elastic members.
In the present invention, the rubber forming the rubbery elastic members of the run flat support member is composed of a two-layer or greater structure. A rubber composition having a high sulfur and resol-type alkyl phenol resin formulation capable of bonding with rubber is arranged at the locations of the rubbery elastic members contacting the ring-shaped metal shell (contact parts) and their vicinity, while a rubber having a superior resistance to heat degradation is arranged at the other locations so as to realize both simplization of the production process and durability of the rubbery elastic members and, in turn, the run flat support member. Due to this, the volume of use of the directly bondable rubber having high bonding characteristics is reduced, and therefore it is possible to reduce the overall cost of the run flat support member and to suppress the problem of sticking, adhesion of rubber to the mold during vulcanization.
The singular forms (“a”, “an”, and “the”) used in the description and the attached claims should be understood as including the plural form unless otherwise clear from the context.
According to the present invention, it is possible to obtain a tire wheel assembly having improved direct bondability between the metal shell and the rubbery elastic members, without coating an organic solvent-based or other adhesive between the metal shell of the run flat support member formed with a high rigidity metal shell and the rubbery elastic members and the rubbery elastic members, more preferably, by securing a predetermined bonding area, it is possible to impart to the run flat support member a bonding strength sufficiently withstanding the load at the time of rim assembly or run flat driving.
The present invention will now be explained more specifically by embodiments shown in the drawings.
For example, as shown in
As explained above, the run flat support member of the tire wheel assembly of the present invention is comprised of a ring-shaped metal shell 4, 5 or 6 and rubbery elastic members 7. The ring-shaped metal shell 4, 5 or 6 forms a continuous support surface at the outside thereof so as to support a punctured or otherwise damaged tire and forms legs by the left thereof and right side walls at the inside. The outside support surface can be shaped in various ways. For example, a flat surface as shown in
In this way, even when forming a support surface, if raising the bonding between the metal and the rubbery elastic members according to the present invention, it is possible to increase the sustained tire run flat driving distance.
The rubbery elastic members 7 are attached to the ends of the two legs of the ring-shaped metal shell 4, 5 or 6 (see
In order to improve the bondability between the rubbery elastic members 7 and the ring-shaped metal shell 4, 5 or 6 and simplify the work efficiency and to reduce the cost, for example, as shown in
The sulfur, which is the essential ingredients of the directly bondable rubber composition used in the present invention, is any sulfur formulated, as a vulcanization agent, into a tire or other rubber composition in the past in an amount of preferably 2 to 10 parts by weight, based upon 100 parts by weight of rubber, more preferably 3 to 6 parts by weight. If the amount is too small, the desired rubber-metal bonding strength cannot be obtained, while conversely if too large, the aged physical properties of the rubber is decreased.
In the present invention, to enable the ring-shaped metal shell and the rubbery elastic members to be directly bonded, a resol-type phenol resin is further formulated in an amount of preferably 1 to 6 parts by weight, more preferably 2 to 5 parts by weight, based upon 100 parts by weight of the diene-based rubber. If the amount is too small, the desired bonding strength cannot be obtained sufficiently, while conversely if too large, scorching easily occurs at the time of processing the rubber.
The resol-type alkyl phenol resin usable in the present invention is a known material. Specifically, it is commercially available from Hitachi Chemical as Hitanol 2501Y etc.
In a preferable embodiment of the present invention, as the above-mentioned directly bondable rubber composition, from the viewpoint of further promoting the reaction at the bonding interface, a cobalt salt of an organic acid is formulated therein, in an amount of, preferably 0.1 to 1 part by weight, more preferably 0.2 to 0.4 part, in terms of a cobalt element, based upon 100 parts by weight of the diene-based rubber. If the amount of the cobalt salt of an organic acid is too small, the desired effect by the increase of the bonding strength is not sufficiently obtained. Conversely, if too large, the cobalt promotes aging of the rubber. As such cobalt salt of an organic acid, specifically cobalt naphthenate, cobalt boroneodecanoate, cobalt stearate, cobalt rosinate, cobalt acetyl acetonate, etc. may be mentioned. Among these, cobalt acetyl acetonate is preferably used.
According to a preferable embodiment of the present invention and from the viewpoint of improvement in the resistance to heat degradation, the directly bondable rubber composition preferably contains, based upon 100 parts by weight of the diene-based rubber, as a reinforcing filler, carbon black/silica in a weight ratio of 10/1 to 1/2 and a total of 40 to 90 parts by weight and further contains, in the case of a silica formulation, a silane coupling agent 1 to 20% by weight, preferably 5 to 15% by weight, based upon the weight of the silica for securing sufficient bonding of the silica and the rubber. As the carbon black and the silica, the conventional carbon blacks and silicas may be used. Further, as the silane coupling agent, a conventional silane coupling agents may be used. Specifically, bis(3-triethoxysilylpropyl)tetrasulfide, bis(3-triethoxysilylpropyl)disulfide, etc. may be mentioned.
The rubbery elastic members according to the present invention, as schematically shown in
As shown in
Note that the general use compound may be a conventional rubber having a superior resistant to heat degradation (high filler formulation and low sulfur formulation).
The method for fabricating the rubbery elastic members from the directly bondable rubber according to the present invention and the general use rubber is not particularly limited. For example, they may be fabricated by simultaneously extruding the directly bondable rubber with the general use rubber by a two-color extruder. Such rubbery elastic members and the ring-shaped metal shell can be bonded by, for example, molding the rubbery elastic members with the metal shell, then heat treating them inside the mold to directly bond the rubber and metal simultaneous with vulcanization of the rubber.
As shown in
Further, the bonded surfaces of the ring-shaped metal shell 5 and the rubbery elastic members 7 should be formed in the axial direction and the radial direction. It is more preferable that the two be substantially equal. By this, a structure able to withstand both force in the axial direction and radial direction occurring at the time of run flat driving is formed.
In
The tire wheel assembly of the present invention is designed to support the weight of an automobile etc. through a punctured or other damaged tire, and, therefore, the ring-shaped metal shell 4, 5 or 6 is comprised of a metal material. As such a metal, iron, stainless steel, aluminum alloy, etc. may be mentioned.
As the rubber forming the parts of said rubbery elastic members other than the vicinity of the bonded surfaces with the ring-shaped metal shell, any general use rubber may be used so long as it can stably support the ring-shaped metal shell. For example, as the rubber, natural rubber, polyisoprene rubber, styrene-butadiene copolymer rubber, polybutadiene rubber, butyl rubber, etc. may be mentioned.
The rubber composition of the rubbery elastic members forming the run flat support member according to the present invention may contain, in addition to the essential ingredients, carbon black, silica, or another filler, a vulcanization or cross-linking agent, a vulcanization or cross-linking accelerator, various oils, an antioxidant, a plasticizer, or other various additives generally formulated for rubber use. The additives may be mixed and vulcanized by a general method to obtain a composition usable for vulcanization or cross-linking. The amounts of these additives can be made the conventional general amounts so far as the object of the present invention is not contravened.
The present invention will now be further explained by Examples, but the present invention is by no means limited to these Examples.
Preparation of Rubbery Elastic Member
Rubbery elastic members (i.e., dimensions: 5.5 mm thickness×2.5 cm width×8 cm length) having the formulations shown in Table I were prepared by mixing the ingredients, other than the vulcanization accelerator and sulfur, in a 2-liter internal mixer for 5 minutes until 150° C., then adding the vulcanization accelerator and sulfur were added thereto in the amounts shown in Table I and mixing the resultant mixture at 80° C. for 3 minutes.
Notes of Table I
*1Natural rubber
*2HAF grade carbon black (Seast N) manufactured by Tokai Carbon
*3Zinc oxide manufactured by Seido Chemical Industry
*4Antioxidant manufactured by Flexsys
*5Silica (Nipsil AQ) manufactured by Nippon Silica Industry
*6Silane coupling agent manufactured by Degussa
*7Cobalt acetyl acetonate (III) manufactured by Kishida Chemical
*8Alkyl phenol resin (Hitanol 2501Y) manufactured by Hitachi Chemical
*9Insoluble sulfur manufactured by Hitachi Chemical
*10Vulcanization accelerator (Noccelar DZ-G) manufactured by Ouchi Shinko Chemical Industries
Next, the rubber elastic members obtained from the rubber compositions A, B and C were used in the combinations shown in Table II with the rubbery elastic members bonded with metal plates manufactured by iron, instead of metal shells (150° C. for 60 minutes). The durability of the run flat tire wheel assemblies thus obtained were decided by the test method shown below. The results are shown in Table II.
Note that the amounts of the rubber compositions A, B and C used shown in Table II are the total amounts of the rubber compositions used. Further, the amount of the adhesive in Comparative Example 1 was the amount, when coating the connection part with a primer and the adhesive one time each to the thicknesses of about 30 μm, while the amounts of use of the rubber compositions near the shells in Examples 1 and 2 were 5 to 20% of the total amounts of the rubber compositions used.
Durability Test
A 2500 cc passenger car was fitted with the test tires and driven with the air pressure inside the front right tire set to 0 kPa and the air pressure inside the other three tires set to 200 kPa at 90 km/h until breakdown. The results are shown as indexed to the value of Comparative Example 1 as 100. The larger the numeral value, the better the durability.
*1 Adhesive Chemlock 200/205 manufactured by Lord Far East
As explained above, bonding of a metal such as iron, stainless steel having a poor bondability with rubber and the rubbery elastic members is extremely difficult. Even if provisionally bonded, often the strength is insufficient or the long term durability is poor. However, according to the present invention, by using, for example, a diene-based rubber, sulfur and a resol-type alkyl phenol resin, it is possible to directly bond a metal and the rubber, without coating an organic solvent-based adhesive between the metal shell and the rubbery elastic members and the durability of the run flat support member is greatly improved.
Number | Date | Country | Kind |
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2004-248304 | Aug 2004 | JP | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/JP05/14963 | 8/10/2005 | WO | 2/27/2007 |