PLY FOR A TIRE

Abstract

A tire includes a pair of axially spaced apart annular bead cores, a carcass ply extending around both bead cores, a tread for engaging a contact surface and being disposed radially outward of the carcass ply, and a belt structure disposed radially between the carcass ply and the tread. The carcass ply includes a plurality of cords embedded in a polymer matrix. The carcass ply has a first radially upper surface and a second radially lower surface disposed opposite the first surface. The first surface defines first portions and second portions interspaced between each first portion. Each first portion has a thickness greater than each second portion thereby forming throated portions between each cord of the plurality of cords.

Claims

1. A tire comprising: a pair of axially spaced apart annular bead cores; a carcass ply extending around both bead cores; a tread for engaging a contact surface, the tread being disposed radially outward of the carcass ply; and a belt structure disposed radially between the carcass ply and the tread, the carcass ply including having a plurality of cords embedded in a polymer matrix, the carcass ply having a first radially upper surface and a second radially lower surface disposed opposite the first surface, the first surface defining first portions and second portions interspaced between each first portion, each first portion having a thickness greater than each second portion thereby forming throated portions between each cord of the plurality of cords.

2. The tire as set forth in claim 1 wherein each first portion joins with an adjacent second portion forming a linear conjunction.

3. The tire as set forth in claim 1 wherein each second portion is defined by a midpoint between two cords on one lateral side of a cord and a midpoint between two cords on the opposite lateral side of the cord.

4. The tire as set forth in claim 1 wherein the first surface has a corduroy appearance.

5. The tire as set forth in claim 1 wherein the second surface has second cylindrical portions with each of the second cylindrical portions being partially concentric with a cylindrical outer surface of an adjacent cord.

6. The tire as set forth in claim 5 wherein each second cylindrical portion joins with an adjacent second cylindrical portion forming a linear conjunction.

7. The tire as set forth in claim 5 wherein each second cylindrical portion is defined by a midpoint between two cords on one lateral side of a cord and a midpoint between two cords on the opposite lateral side of the cord.

8. The tire as set forth in claim 5 wherein the second surface has a corduroy appearance.

9. The tire as set forth in claim 1 wherein the belt structure has a first radially upper belt surface and a second radially lower belt surface disposed opposite the first belt surface, the first belt surface having first belt cylindrical portions with each of the first belt cylindrical portions being partially concentric with a cylindrical outer surface of an adjacent belt cord.

10. The tire as set forth in claim 9 wherein the first belt surface has a corduroy appearance.

11. A method for producing a corduroy ply, the method comprises the steps of: concentrically attaching a first topping rubber to a periphery of each of a plurality of cords; forming an array of cords coated with the first topping rubber; concentrically attaching a second topping rubber to a periphery of each of the plurality of cords; and forming a cord ply having a corduroy first surface and a corduroy second surface opposite the first corduroy surface.

12. The method as set forth in claim 11 further including the step of modifying a first planar surface and a second planar surface.

13. The method as set forth in claim 11 further including the step of removing rubber from a first planar surface of the cord ply and a second planar surface of the cord ply.

14. The method as set forth in claim 11 further including the step of calendering the first topping rubber and the second topping rubber.

15. The method as set forth in claim 11 further including the step of removing throat material between each cord of the plurality of cords.

16. The method as set forth in claim 11 wherein pressure of the first topping rubber in a topping chamber is 5,000 kPa or higher.

17. The method as set forth in claim 16 wherein pressure of the second topping rubber in the topping chamber is 5,000 kPa or higher.

18. The method as set forth in claim 11 wherein a time interval between the attaching steps is 10 minutes or less.

19. The method as set forth in claim 11 wherein the first topping rubber has the same rubber composite as that of the second topping rubber.

20. The method as set forth in claim 11 wherein the first topping rubber has a rubber composite with greater complex elastic modulus than that of the second topping rubber.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0095] The present invention will be described by way of example and with reference to the accompanying drawings, in which:

[0096] FIG. 1 schematically shows an example apparatus for producing a ply in accordance with the present invention;

[0097] FIG. 2 schematically shows an enlarged perspective view of part of the example apparatus of FIG. 1; and

[0098] FIG. 3 schematically shows a cross-section construction of a ply in accordance with the present invention.

DETAILED DESCRIPTION OF EXAMPLES OF THE PRESENT INVENTION

[0099] FIG. 1 shows an example apparatus 1 for producing a ply in accordance with the present invention. The ply may be used in any structure of a tire, such as carcass, belt, overlay, flipper, chipper, etc. This apparatus 1 is only one example and the apparatus may not be limited to the specific structure of FIGS. 1-2. Cords 2 may be pulled out from spools 3 arranged in parallel to each other and supplied to a first topping apparatus 5. A suitable structure for the cords 2 is not limited, and the structure may be selected in accordance with the ply, such as 15, 14, 13, 2+2, 2+3, monofilament, etc. Although the cords 2 are shown as monofilaments in FIGS. 1-3, a stranded cord comprising a plurality of strands/filaments may alternatively be used. The cords 2 may be constructed of steel, carbon fiber, resin, rayon, aramid, glass fiber, rayon, and/or other suitable material.

[0100] When the cords 2 pass through an arranging roll 4, the cords 2 may be substantially in parallel to each other. The arranging roll 4 may include rotatable roll bodies 4A, 4B which sandwich the cords 2 from above and below. In the example shown, an outer peripheral surface of at least one of the roll bodies may be formed with a guide groove into which a portion of the cords 2 may be fitted. The guide groove may be formed in the circumferential direction of the roll bodies 4A, 4B. Thus, a plurality of the cords 2 may discharge from the arranging roll 4 smoothly and without resistance. Alternatively, a comb-like body with slit-like guide hole may be provided instead of the roll 4.

[0101] In the example of FIGS. 1-2, the first topping apparatus 5 includes a small rubber extruding portion 5A and a rubber attaching tool 5B mounted on a tip end of the rubber extruding portion. The rubber extruding portion 5A may include an input port 5A1 into which material of first topping rubber is supplied and an extruding port 5A2 from which kneaded and plasticized first topping rubber is discharged to the cords 2. The rubber extruding portion 5A may include a screw-type rubber extruder with a screw shaft rotated by a motor M. The rubber attaching tool 5B may include a pipe-like body 6 connected to the extruding port 5A2 of the rubber extruding portion 5A.

[0102] The pipe-like body 6 may include a hollow topping chamber 6C therein. A distal end 6A of the pipe-like body 6 may be closed and a posterior end 6B of the pipe-like body 6 may include an opening which may communicate with the extruding port 5A2. If the posterior end 6B of the pipe-like body 6 is fixed to the rubber extruding portion 5A, using a flange for example, first topping rubber may supply the topping chamber 6C of the pipe-like body 6 under a predetermined pressure. The pipe-like body 6 may be longitudinally split into two pieces for facilitating maintenance of the topping chamber 6C.

[0103] As shown in FIG. 2, the pipe-like body 6 may include a plurality of first guiding holes 9 at its upstream wall surface through which the cords 2 may pass. The first holes 9 may be formed at distances from one another in a longitudinal direction of the pipe-like body 6. The base body 6 may also include second coating holes 10 at its downstream wall surface corresponding to the first holes 9. The second holes 10 may be concentric with the first holes 9 and have a diameter greater than a diameter of the first holes 9. The rubber attaching tool 5B may further include a pressure sensor 8 for detecting pressure in the topping chamber 6C. A signal from the pressure sensor 8 may be transmitted to a control apparatus (not shown) of the rubber extruding portion 5A. A rubber amount for supplying the rubber extruding portion 5A may thereby automatically control the rubber pressure of the topping chamber 6C and maintain the pressure at a predetermined optimal value.

[0104] The cords 2, arranged in parallel to one another by the roll 4, may thus pass through the topping chamber 6C from the first holes 9 of the pipe-like body 6 to the second holes 10. The cords 2 may be pulled out straightly such that the cords 2 align with respect to a coincident center of each of the first holes 9 and second holes 10. In the topping chamber 6C, first topping rubber r1 supplied under the predetermined rubber pressure may permeate/fill in a gap between the cords 2 and attach to a periphery of the cords. In the second hole 10, the first topping rubber r1 attached to the cords 2 may be sliced off except a thin coating layer 11 concentrically attached to periphery of the cords.

[0105] Since the cords 2 pass through the high pressure first topping rubber r1, even if the passing speed is fast, the first topping rubber r1 may sufficiently and effectively permeate the fine gap between the cords 2. As stated above, the pressure in the topping chamber 6C may be controlled in a desired range by the pressure sensor 8. Therefore, the attaching efficiency of the first topping rubber r1 to the cords 2 may be achieved.

[0106] The pressure in the topping chamber 6C may be 5,000 kPa, 10,000 kPa, or higher. If the pressure in the topping chamber 6C is less than 5,000 kPa, the attaching or permeating effect of first topping rubber r1 with respect to the cords 2 may be less than acceptable. If the pressure is excessively high, the first topping rubber r1 may flow out undesirably from the first and second holes 9, 10. Also, resistance caused when the cords 2 pass through the first topping rubber r1 may become greater and the productivity deteriorated. The speed of the cords 2 may be in a range of 5 to 30 m/min or in a range of 10 to 30 m/min.

[0107] The diameter of the first holes 9 may be in a range of 101% to 107% of the outer diameter of the cords 2 or in a range of 103% to 105% thereof. If the diameter of the first holes 9 is less than 101% of the outer diameter of the cords 2, the cords may be damaged. If the diameter exceeds 107%, centering of the cords 2 may become problematic and an amount of topping rubber flowing out from the gap between the cords may become excessive.

[0108] The diameter of the second holes 10 may be in a range of 102% to 110% of the outer diameter of the cords or in a range of 103% to 105% thereof. If the diameter of the second holes 10 is less than 102% of the outer diameter of the cords, the coating thickness of the first topping rubber r1 may become excessively small and may lead to peeling off of the first topping rubber. If the diameter exceeds 107%, the coating thickness may become excessively thick and undesirably increase the overall ply thickness. The coating thickness may be between 0.1 mm and 0.5 mm.

[0109] Next, a second topping step may attach a second topping rubber r2 to a surface of a cord array 12 in which the cords 2 and coating of first topping rubber r1 are arranged. Four calender rolls 13 may be used (FIG. 1). Both surfaces of the cord array 12 having rubber may be coated with second topping rubbers r2 and a sheet-like cord ply 15, such as that of FIG. 3, may be formed.

[0110] As shown in FIGS. 1 and 3 and in accordance with the present invention, a supplemental die 14 may be further included downstream of the calender rolls 13. The die 14 may include a die plate for modifying the planar upper and lower surfaces of the sheet like ply 15 such that the throated ply 16 of FIG. 3 is achieved. The die 14 may remove rubber r2 from the sheet-like ply 15 such that an upper surface 18 and a lower surface 19 of the throated ply 16 may have cylindrical portions 21 with each of the cylindrical portions being partially concentric with a cylindrical outer surface of its adjacent cord 2. The joining of each cylindrical portion 21 with an adjacent cylindrical portion may form a linear conjunction with each cylindrical portion being defined by a midpoint 23 between two cords on one side of a cord 22 and a midpoint 23 between two cords on the opposite side of the cord 22.

[0111] The design of the throated ply 16 may create a volume neutral ply (compared to traditional sheet-like ply 15) with rubber on top and bottom of the cord 22 and a notch or throat between each cord 2. This may result in a more even strain distribution of rubber within the ply 16 during tire shaping, which may produce a more even cord spacing in the cured tire. The upper and lower surfaces 18, 19 of the ply 16 may in one example thereby have an appearance similar to corduroy fabric (FIG. 3). Additionally, any geometry that creates a ply 16 with a varying gauge along the upper and lower surfaces 18, 19 may result in the even strain distribution described above.

[0112] Consequently, any example ply 16 with additional topping gauge placed immediately above and/or below each cord 22 and less gauge placed between the cords 22 may be such a geometry. Example geometries may further include saw-toothed, square-toothed, rectangular-toothed, non-concentric cylindrical, or any suitable repeating geometry that meets this description. Such a ply 16 may be used with any suitable tire, such as that disclosed in US 2002/0134482, incorporated herein by reference in its entirety.

[0113] Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims.