A composite reinforcer that can adhere directly to a diene rubber matrix is usable as a reinforcing element for a pneumatic tire. The composite reinforcer includes at least one reinforcing thread, such as a carbon steel cord. Covering each thread individually or several threads collectively is a layer of a thermoplastic polymer composition. The thermoplastic polymer composition includes at least one thermoplastic polymer have a glass transition temperature that is positive, a poly(p-phenylene ether) (PPE), and a functionalized unsaturated thermoplastic styrene (TPS) elastomer having a glass transition temperature that is negative. The TPS elastomer includes a functional group selected from: an epoxide group, a carboxyl group, an acid anhydride group, and an ester group. A process for manufacturing such a composite reinforcer is presented, as well as a process for producing a rubber article, especially a pneumatic tire, incorporating such a composite reinforcer.

A composite reinforcer that can adhere directly to a diene rubber matrix is usable as a reinforcing element for a pneumatic tire. The composite reinforcer includes at least one reinforcing thread, such as a carbon steel cord. Covering each thread individually or several threads collectively is a layer of a thermoplastic polymer composition. The thermoplastic polymer composition includes at least one thermoplastic polymer have a glass transition temperature that is positive, a poly(p-phenylene ether) (PPE), and a functionalized unsaturated thermoplastic styrene (TPS) elastomer having a glass transition temperature that is negative. The TPS elastomer includes a functional group selected from: an epoxide group, a carboxyl group, an acid anhydride group, and an ester group. A process for manufacturing such a composite reinforcer is presented, as well as a process for producing a rubber article, especially a pneumatic tire, incorporating such a composite reinforcer.

A topping sheet forming method includes: a division step of cylindrically winding a textile original fabric, obtained by weaving longitudinally aligned tire cords into a cord fabric by use of weft yarns, to form an original fabric roll and cutting off the weft yarns in predetermined widthwise positions by using a wire wound on the original fabric roll in a predetermined winding angle range to divide the textile original fabric into narrow textile original fabrics; and a topping step of topping at least one surface of each of the narrow textile original fabrics with unvulcanized rubber.

A topping sheet forming method includes: a division step of cylindrically winding a textile original fabric, obtained by weaving longitudinally aligned tire cords into a cord fabric by use of weft yarns, to form an original fabric roll and cutting off the weft yarns in predetermined widthwise positions by using a wire wound on the original fabric roll in a predetermined winding angle range to divide the textile original fabric into narrow textile original fabrics; and a topping step of topping at least one surface of each of the narrow textile original fabrics with unvulcanized rubber.

A topping sheet forming method includes: feeding a textile original fabric, obtained by weaving longitudinally aligned tire cords into a cord fabric by use of weft yams; cutting off the weft yarns at a predetermined widthwise position to divide the textile original fabric into a plurality of narrow textile original fabrics; and topping at least one surface of the narrow textile original fabric with unvulcanized rubber.

A topping sheet forming method includes: a feeding and division step of feeding a textile original fabric, obtained by weaving longitudinally aligned tire cords into a cord fabric by use of weft yams, and cutting off the weft yarns in predetermined widthwise positions to divide the textile original fabric into a plurality of narrow textile original fabrics; a calender step of topping, with unvulcanized rubber, at least one surface of one narrow textile original fabric out of the divided narrow textile original fabrics; and a wind-up step of winding up the other narrow textile original fabrics out of the divided narrow textile original fabrics.

A topping sheet forming method includes: a feeding and division step of feeding a textile original fabric, obtained by weaving longitudinally aligned tire cords into a cord fabric by use of weft yarns, and cutting off the weft yarns in predetermined widthwise positions to divide the textile original fabric into a plurality of narrow textile original fabrics; and a topping step of topping at least one surface of each of the narrow textile original fabrics with unvulcanized rubber.

To provide a pneumatic tire 34 in which weight reduction is achieved without deteriorating internal pressure maintaining performance. The tire 34 includes a liner 46 located inward of a carcass 42. The liner 46 includes a first inner liner 66 extending on and between one of beads and the other of the beads and along and inward of the carcass 42; and a pair of second inner liners 68 extending from ends 62a of a belt 44, respectively, along the first inner liner 66 substantially inward in a radial direction. The second inner liners 68 are located between the first inner liner 66 and the carcass 42. The first inner liner 66 is formed by a first rubber composition being crosslinked. A base rubber of the first rubber composition includes a butyl rubber. Each second inner liner 68 is formed by a second rubber composition being crosslinked. A base rubber of the second rubber composition includes a diene rubber.

To provide a pneumatic tire 34 in which weight reduction is achieved without deteriorating internal pressure maintaining performance. The tire 34 includes a liner 46 located inward of a carcass 42. The liner 46 includes a first inner liner 66 extending on and between one of beads and the other of the beads and along and inward of the carcass 42; and a pair of second inner liners 68 extending from ends 62a of a belt 44, respectively, along the first inner liner 66 substantially inward in a radial direction. The second inner liners 68 are located between the first inner liner 66 and the carcass 42. The first inner liner 66 is formed by a first rubber composition being crosslinked. A base rubber of the first rubber composition includes a butyl rubber. Each second inner liner 68 is formed by a second rubber composition being crosslinked. A base rubber of the second rubber composition includes a diene rubber.

The present invention discloses a preparation method of polyester cord fabric with low denier and high modulus, including steps of: spinning, reducing melt discharge volume for extruding yarn with denier of 500-1000 D; using high-speed motor and heat roller, spinning speed of 6000-6500 m/min to produce raw yarn; performing initial and repeat twisting of raw yarn by straight twisting machine; performing weaving of twisted yarn using Dornier air-jet loom to produce cord fabric, when weaving and reeding-in, using two into a reed way, adding creel roller bearing and creel single spindle tension control belt to improve uniformity; performing dipping of cord fabric using two-bath dipping, adjusting temperature to 250-260 degrees Celsius, tension to 0.3-2.9 daN/each yarn of key area, running speed of yarn to 55-70 m/min. The polyester cord fabric with low denier and high modulus can reduce rolling resistance and fuel consumption, and improve performance.