MOLDING PROCESS FOR EASED RELEASE OF A TIRE

Abstract

The invention relates to a molding process wherein a green tire is formed and then molded within a tire mold, the tire mold having one or more moving elements configured to move at least into an open configuration and a closed configuration of the tire mold. The tire mold further comprises a mold cavity, and wherein the process comprises the step of injecting one or more gases in the mold cavity after the tire was cured and before opening the tire mold to retrieve the molded tire.

Claims

1. A molding process wherein a green tire is formed and then molded within a tire mold; the tire mold having one or more moving elements configured to move at least into an open configuration and a closed configuration of the tire mold; the tire mold comprising an actuating ring, a top plate, a bottom plate, upper and lower side members, and a plurality of mold segments and slide blocks; the upper and lower side members and the plurality of mold segments defining a mold cavity, and one or more channels in the tire mold, wherein at least one channel of the one or more channels is placed in the bottom plate or in the actuating ring or in the top plate; wherein the process comprises the steps of: providing a tire mold; placing the green tire within the mold cavity; closing the tire mold; curing the tire; injecting one or more gases in the mold cavity; opening the tire mold to retrieve the molded tire; and wherein the gas is injected using the one or more channels in the tire mold.

2. The molding process according to claim 1 wherein the tire mold is airtight and the tire mold provided has one or more seal members and wherein the step of closing the tire mold comprises sealing the tire mold and drawing a vacuum on the mold cavity.

3. The molding process according to claim 2 wherein the step of injecting gas is performed or at least started while the tire mold is still sealed.

4. The molding process according to claim 1 wherein in the step of injecting gas, the pressure in the tire mold is at most 2.1 MPa or at most 1.0 MPa or at most 0.7 MPa.

5. The molding process according to claim 1 wherein in the step of injecting gas, the pressure in the tire mold is ranging from 0.12 to 2.1 MPa or from 0.2 to 0.7 MPa.

6. The molding process according to claim 2, comprising drawing a vacuum on the mold cavity before the curing step using one or more channels and wherein the step of injecting gas is performed using at least one channel used to draw the vacuum.

7. (canceled)

8. The molding process according to claim 1 wherein the tire mold comprises a molding surface coated with one or more of a fluorocarbon polymer, a CrNi alloy, and a fluorinated diamond-like carbon material.

9. The molding process according to claim 1 wherein the tire mold is configured for molding all-season or winter tires so that the molding surface comprises a plurality of forming elements that form sipes on the all-season or winter tires.

10. The molding process according to claim 1 wherein in the step of injecting one or more gases, the gas is air so that the step is a step of injecting air.

11. The molding process according to claim 10 wherein the step of injecting air comprises filtering the air before it is injected.

12. A molding process wherein a green tire is formed and then molded within a tire mold; the tire mold having one or more moving elements configured to move at least into an open configuration and a closed configuration of the tire mold; the tire mold comprising a mold cavity; wherein the process comprises the steps of: providing a tire mold being airtight, having one or more closing seal members, and being optionally ventless; placing the green tire within the mold cavity; closing and sealing the tire mold and drawing a vacuum on the mold cavity; curing the tire; injecting one or more gases in the mold cavity, wherein the step of injecting one or more gases is performed for at least 1 second and at most 20 minutes; and opening the tire mold to retrieve the molded tire.

13. The molding process according to claim 12 wherein the step of injecting one or more gases is performed one of before opening the tire mold or during opening the tire mold while the tire mold is still airtight.

14. (canceled)

15. The molding process according to claim 12 wherein the step of injecting one or more gases is conducted to create a pressure inside the mold cavity greater than the atmospheric pressure or of at least 0.2 MPa.

16. The molding process according to claim 12 wherein the tire mold comprises a molding surface with a low-adhesion coating layer made of or comprising polytetrafluoroethylene.

17. A molding process wherein a green tire is formed and then molded within a tire mold; the tire mold having one or more moving elements configured to move at least into an open configuration and a closed configuration of the tire mold; wherein the process comprises the steps of: providing a ventless tire mold or an airtight tire mold; placing the green tire within the mold cavity; closing and sealing the tire mold and drawing a vacuum in the mold cavity; curing the tire; injecting air in the mold cavity to release the tire from the tire mold, wherein the step of injecting air comprises filtering the air before it is injected; and opening the tire mold to retrieve the molded tire.

18. (canceled)

19. The molding process according to claim 17 wherein both steps of drawing a vacuum in the mold cavity and injecting air in the mold cavity are performed using the same channels.

20. The molding process according to claim 19 wherein the tire mold comprises a bottom plate and wherein at least one channel is arranged in the bottom plate.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0067] The invention will be described by way of example and with reference to the accompanying drawings in which:

[0068] FIG. 1 is a partial cross-sectional view of a tire mold according to an embodiment of the invention; and

[0069] FIG. 2 is a view of connecting means to connect the vacuum and/or injection pump or the reservoir of compressed gas to the bottom plate of a tire mold.

DETAILED DESCRIPTION OF THE INVENTION

[0070] The following is an explanation of a process and a tire mold according to embodiments of the present invention for molding a pneumatic or a non-pneumatic tire.

[0071] The molding process and the tire mold in accordance with embodiments of the invention are remarkable in that they provide a device to inject a gas such as air in the mold cavity after curing of a tire to ease the release of the tire from the tire mold.

[0072] In the molding process, a green tire, having tread, sidewall and bead portions, is formed and then molded within a tire mold. The tire mold has one or more moving elements configured to move at least into an open configuration and a closed configuration of the tire mold comprising an actuating ring, a top plate, a bottom plate, upper and lower side members, and a plurality of mold segments and slide blocks. The upper and lower side members and the plurality of mold segments define a mold cavity wherein the process comprises the steps of: [0073] providing a tire mold; [0074] placing the green tire within the mold cavity; [0075] curing the tire; [0076] injecting one or more gases in the mold cavity; and [0077] opening the tire mold to retrieve the molded tire.

[0078] The tire mold can be a conventional tire mold or a ventless tire mold or an airtight tire mold. In a preferred embodiment, the tire mold is airtight.

[0079] In such a case in which a green tire having tread, sidewall and bead portions is formed and then molded within a tire mold, the tire mold has one or more moving elements configured to move at least into an open configuration and a closed configuration of the tire mold, wherein the tire mold comprises an actuating ring, a top plate, a bottom plate, upper and lower side members, a plurality of mold segments and slide blocks, as well as a vacuum device. The upper and lower side members and the plurality of mold segments define a mold cavity and the tire mold further comprises means for sealing the mold cavity which includes one or more closing seal members, and wherein the process comprises: [0080] providing a tire mold having one or more closing seal members; [0081] placing the green tire within the mold cavity; [0082] closing the tire mold and drawing a vacuum on the mold cavity; [0083] curing the tire; [0084] injecting one or more gases in the mold cavity; and [0085] opening the tire mold to retrieve the molded tire.

[0086] Reference is made to FIG. 1 which illustrates a first embodiment of a tire mold 1. The tire mold 1 comprises a plurality of mold segments which are arranged to form an annular ring when assembled. The outer tread surface of a tire is formed by the inner molding surface 3 of the mold segments which corresponds to the external surface tread molding element. The inner molding surface has a plurality of sipes and/or blades (not shown) to mold the tread pattern in a green tire (not represented). The mold segments may be radially movable to allow assembly and disassembly of the tire mold about a green tire and a molded tire respectively.

[0087] The tire mold 1 further comprises first and second sidewall plates 7, 9 for molding the sidewalls of the tire. Each sidewall plate 7, 9 joins with the mold segments to form a smooth continuous surface from the tire tread to the sidewall. Each sidewall plate 7, 9 may comprise an optional radially outer lip 11 forming an essentially L-shaped recess for receiving a first and second flanged end of the mold segment therein. Each sidewall plate 7, 9 further comprises an optional radially inner extension or lip 13 forming a second L-shaped recess for receiving a mold bead ring 15, 17 therein. Each bead ring 15, 17 has a radiused portion for receiving a bead area of a green tire thereon. The upper and lower sidewall plates 7, 9 together with the plurality of tread segments and the top and bottom bead rings 15, 17 cooperate to define a mold cavity 5 for molding a green tire.

[0088] The mold segment can comprise a tread molding element 19 and a support element 21 or comprises a tread molding element integral with the support element or comprises a tread molding element integral with the support element and with a slide block.

[0089] The mold segment can be formed from one or two elements. In the embodiment of FIG. 1, the mold segments are formed from two elements being a tread molding element 19 and a support element 21. However, in another embodiment, the tread molding element and the support element are integral and form a single element being the mold segment.

[0090] Preferably, irrespective of whether the mold segment is formed from one or two elements, the tire mold 1 is angularly segmented and further comprises a container housing.

[0091] The container housing typically includes top and bottom plates 23, 25. The bottom plate 23 has an inner annulus for supporting the sidewall plate 9 and the bead ring 17. Surrounding the segments are a plurality of slide blocks 27. The slide blocks 27 have flanged ends for receiving and supporting the segments therein. The slide blocks 27 have a top and a bottom surface for contacting the top and bottom plates 23, 25 and optional wear plates (not shown). Slide blocks 27 are slidable in a radial direction. The container housing further comprises an annular actuating ring 31. The inner radial surface of the actuating ring 31 is angled for engagement with an outer angled surface of the slide blocks 27. In the embodiment shown in FIG. 1, the actuating ring 31 is one of the one or more moving elements configured to move at least in an open configuration and a closed configuration of the tire mold. However, the person skilled in the art may adapt the invention to a tire mold configuration wherein the actuating ring is not movable. Such configuration is known to the person skilled in the art and described in U.S. Pat. No. 7,056,109.

[0092] When the actuating ring 31 is one of the one or more moving elements, as the actuating ring 31 is lowered from an opened configuration to a closed configuration, the inner radial surface of the actuating ring 31 engages the outer angled surface of slide blocks 27, causing the slide blocks to slide radially inward. The camming action of the actuating ring 31 moves the slide blocks 27 radially inward due to a wedge effect. As slide blocks 27 move radially inward, the radially inner surface of the slide blocks 27 engages the outer surface of the adjacent mold segment, moving the mold segment radially inward as the actuating ring 31 is lowered into its closed configuration that defines the diameter-reducing limit position, causing the blades and/or the sipes to cut the surface of the green tire.

[0093] The tire mold 1 can be airtight and/or ventless. Preferably the tire mold is airtight.

[0094] In embodiments wherein the tire mold 1 is a ventless tire mold that is airtight or an airtight tire mold, it further comprises a plurality of seal members 33, 35. A bottom seal member 33 is placed between the contact surface of the bottom plate 23 and the second sidewall plate 9. Similarly, a top seal member 35 is placed between the contact surface of the top plate 25 and the first sidewall plate 7.

[0095] The tire mold 1 further comprises closing seal members 37, 39 arranged to seal the mold cavity 5 slightly before the tire mold 1 is closed, for example, before the actuating ring 31 reaches its closed configuration or position. For example, an upper closing seal member 37 is arranged on a groove of the top plate 25 and cooperates with the actuating ring 31 to form a structure impervious to air. Similarly, a bottom seal member 39 is arranged on the bottom plate 23 to cooperate with the actuating ring 31 to form a structure impervious to air. Therefore, when coupled with the upper closing seal member 37 and the lower closing seal member 39, the actuating ring 31 provide an air barrier for drawing a vacuum in the tire mold cavity 5.

[0096] For example, the upper closing seal member 37 and the lower closing seal member 39 are of an O-ring type, as illustrated in FIG. 1. However, in some embodiments, at least one of the closing seal members 37, 39 can be of a T-(shaped)-type. In the embodiment illustrated in FIG. 1, both the upper and the lower closing seal members 37, 39 are O-ring seal members. However, the invention encompasses also embodiments in which both the upper and the lower closing seal members are T-seal members, or embodiments in which the upper closing seal member is an O-ring seal member and/or the lower closing seal member is a T-seal member. Alternatively, the upper closing seal member is a T-seal member and the lower closing seal member is an O-ring seal member.

[0097] In preferred embodiments, the upper closing seal member 37 and the lower closing seal member 39 are of the O-ring type since they will still be airtight when gas is injected into the mold cavity.

[0098] The tire mold 1 may initially be partly closed and already airtight in the not yet fully closed configuration. This allows to efficiently remove air between the surface of the green tire and the inner molding surface 3 and to avoid the formation of bubbles. The air may be evacuated and, while pumping the air present in the mold cavity 5, the tire mold 1 is fully closed.

[0099] It is understood that in embodiments in which the tire mold 1 is a ventless tire mold that is airtight or wherein the tire mold 1 is an airtight tire mold, the tire mold 1 is associated with one or more vacuum pumps (not shown). Air is evacuated from the airtight tire mold 1 (and therefore from the mold cavity 5) through one or more channels 41. The embodiment illustrated in FIGS. 1 and 2 shows such a channel 41 arranged in the bottom plate 23. However, the person skilled in the art may consider other locations for the one or more channels in addition or alternatively to the channel present in the bottom plate 23. For example, one or more channels can be arranged in the actuating ring 31 and/or in the top plate 25. On FIG. 2, a plug 43 is fixed to the mouth of a channel 41 arranged in a bottom plate 23 to bring the molding cavity in fluid (flow) communication alternatively with a vacuum pump and an injection pump (not shown) or alternatively with a vacuum pump and reservoir of compressed gas (not shown).

[0100] After the tire mold 1 is closed, the vacuum pump may be disconnected, for example, during the cure of the tire. It is understood that during the cure, the tire mold is preferably sealed.

[0101] The process is remarkable as after curing the tire and before opening the tire mold to retrieve a molded tire (i.e., a cured tire), it comprises a step of injecting one or more gases in the mold cavity. The one or more gases are or comprise preferably air. The injected gas will infiltrate between the molded tire and the inner molding surface to assist the release of the tire from the mold segments and the sidewall plates. Injecting gas in the mold cavity before the opening of the tire mold or during the (very) beginning of opening the tire mold will remove the suction cup effect between the tire itself and mold segments or sidewall plates. The injection of gas in the mold cavity has the further advantage that it will release or at least ease the release of the tire and avoid any tire scrap or, in some cases, mold segment defect.

[0102] It is understood that the one or more gases are injected in a different place than from where a curing bladder (when present) inflates. A curing bladder is a cylindrical bag that is typically mounted in a lower section of the tire curing press and forms a part of the press and mold assembly. The green tire is positioned over the bladder in the bottom half of the mold. When the mold is closed, pressurized steam, air, hot water, or inert gas (nitrogen) is introduced into the bladder to provide internal heat and pressure for the tire shaping and curing process. It is understood that gases used in connection with inflating curing bladders are injected before the curing step and/or in another place. According to the invention, the one or more gases are injected after the curing step and/or between the molded tire and the inner molding surface so as to separate those.

[0103] For example, the one or more gases injected are or comprise air, so that in the step of injecting gas, the gas is air. With preference, the step of injecting air comprises filtering the air before it is injected.

[0104] In case the tire mold is a conventional tire mold, the quantity of gas injected needs to be important to generate pressure inside the mold cavity. Thus, in a preferred embodiment, the tire mold is a ventless tire mold that is airtight or wherein the tire mold is an airtight tire mold and the step of injecting gas is performed or at least started while the tire mold is still sealed so that it is easier to generate a pressure inside the tire mold. Injection of gas in the mold cavity generates a pressure in the mold cavity that is above the atmospheric pressure.

[0105] The pressure generated by the injection of one or more gases is greater than the atmospheric pressure but should not be so important that it may damage the tire. For example, for the step of injecting gas, the pressure in the tire mold is at most 2.1 MPa, preferably at most 1.8 MPa, or even more preferably at most 1.5 MPa, at most 1.0 MPa, at most 0.9 MPa, at most 0.7 MPa, at most 0.6 MPa, or at most 0.5 MPa.

[0106] For example, for the step of injecting gas, the pressure in the tire mold is ranging from 0.12 to 2.1 MPa, preferably from 0.13 to 1.8 MPa from 0.14 to 1.5 MPa, from 0.15 to 1.0 MPa, from 0.18 to 0.9 MPa, from 0.2 to 0.7 MPa, from 0.25 to 0.6 MPa, or from 0.3 to 0.5 MPa.

[0107] For example, the step of injecting one or more gases is conducted to create a pressure inside the mold cavity greater than the atmospheric pressure or of at least 0.2 MPa.

[0108] For example, the step of injecting gas is performed for at least 1 second and at most 20 minutes, preferably for at least 2 seconds and at most 10 minutes, more preferably for at least 5 seconds and at most 5 minutes, and even more preferably for at least 10 seconds and at most 1 minute.

[0109] For example, the step of injecting gas is performed for at most 20 minutes, preferably at most 10 minutes, more preferably at most 5 minutes, even more preferably at most 1 minute.

[0110] For example, the step of injecting gas is performed for at least 1 second, preferably at least 2 seconds, more preferably for at least 5 seconds, even more preferably at least 10 seconds.

[0111] The one or more gases are injected using an injection pump (such as a gas compressor) and/or a reservoir of compressed gas and can be injected in the mold cavity by any suitable means. The tire mold comprises therefore one or more channels that can be used for gas injection. The one or more channels for gas injection are the same or different from the one or more channels used for drawing a vacuum. In a preferred embodiment, the step of injecting gas is performed using at least one channel also used to draw the vacuum in the mold cavity.

[0112] In an embodiment, at least one channel 41 is in fluid (flow) communication with a switch valve. Said switch valve is connected to a vacuum pump and to an injection pump (such as a gas compressor) and/or to a reservoir of compressed gas (such as compressed air), the switch valve being configured for selectively connecting the mold cavity to the vacuum pump or to the injection pump or the reservoir of compressed gas. A reservoir of compressed gas could for instance be a gas tank or gas container.

[0113] Whether they are the same or different, the one or more gases may be injected using one or more channels in the tire mold, wherein at least one channel of the one or more channels is provided in the bottom element or in the actuating ring or in the top element.

[0114] To facilitate the release of the tire by air injection, the inner mold surface 3 is preferably covered by a coating layer that promotes low adhesion of the molded tire on the inner mold surface 3. Such coating layers as such are well known to the person skilled in the art and are described for example in EP2012991, CN108239767, CN108193173 which are incorporated by reference.

[0115] For example, the coating layer comprises a fluorocarbon polymer (such as polytetrafluoroethylene (PTFE)) or a CrNi alloy or a fluored diamond-like carbon (F-DLC) material. With preference, the coating layer is made of or comprises polytetrafluoroethylene (PTFE).

[0116] The present process can be used for molding any type of tire but is particularly useful for molding all-seasons tires or winter tires so that the molding surface comprises a plurality of sipes.

[0117] 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.