METHOD OF CONTROLLING A PHASE OF MOULDING AN ANNULAR FIXING STRUCTURE AND A TYRE INCLUDING AN ANNULAR FIXING STRUCTURE

Abstract

A tyre includes a toroidal ring-shaped carcass structure with at least one carcass ply associated with at least one annular fixing structure, as well as a tread band positioned radially externally with respect to the carcass structure. The annular fixing structure includes a radially inner and axially inner surface and a radially inner and axially outer surface, the surfaces being substantially opposed to each other. The radially inner and axially inner surface and radially inner and axially outer surface are shaped by successive application of a first squeezing pressure produced by a first surface and a second surface of a curing mould that are brought towards each other, as well as a second squeezing pressure produced by bringing the first and second surfaces closer together. The radially inner and axially inner surface and/or radially inner axially outer surface have a shape that includes air evacuation channels.

Claims

1-28. (canceled)

29. A tyre comprising: a toroidal ring-shaped carcass structure, comprising at least one carcass ply associated with at least one annular fixing structure; and a tread band positioned radially externally with respect to said carcass structure, wherein said annular fixing structure comprises a radially inner and axially inner surface and a radially inner and axially outer surface, the surfaces being substantially opposed to each other, said radially inner and axially inner surface and said radially inner and axially outer surface having been shaped by successive application thereto of: a first squeezing pressure produced by using a first surface and a second surface of a curing mould which are brought towards each other; and a second squeezing pressure produced by using said first and said second surfaces which are brought closer together, and wherein said radially inner and axially inner surface and/or said radially inner and axially outer surface have a shape including air evacuation channels.

30. The tyre according to claim 29, wherein said radially inner and axially inner surface and said radially inner and axially outer surface have been shaped by application thereto, after said second squeezing pressure, of a third squeezing pressure produced by bringing said first and said second surfaces still closer to each other.

31. The tyre according to claim 30, wherein shaping of said radially inner and axially inner surface and of said radially inner and axially outer surface is carried out by squeezing a portion of said radially inner and axially inner surface against said first surface of the curing mould at said first squeezing pressure, and by squeezing a portion of said radially inner and axially outer surface against said second surface of the curing mould.

32. The tyre according to claim 31, wherein the shaping of said radially inner and axially inner surface and of said radially inner and axially outer surface is carried out by squeezing said portion of said radially inner and axially inner surface against said first surface of the curing mould at said second squeezing pressure, and by squeezing said portion of said radially inner and axially outer surface against said second surface of the curing mould.

33. The tyre according to claim 31, wherein the distance between a radially outermost point and a radially innermost point of said radially inner and axially inner surface portion projected in a circumferential plane is in a range from approximately 5 mm to approximately 40 mm.

34. The tyre according to claim 33, wherein said distance is in a range from approximately 7 mm to approximately 20 mm.

35. The tyre according to claim 34, wherein said portion of said radially inner and axially inner surface and/or said portion of said radially inner and axially outer surface has a substantially flat shape.

36. The tyre according to claim 34, wherein said portion of said radially inner and axially inner surface and/or said portion of said radially inner and axially outer surface has an undulating shape.

37. The tyre according to claim 34, wherein said portion of said radially inner and axially inner surface and/or said portion of said radially inner and axially outer surface has a shape including a plurality of lobes.

Description

[0074] This description is given below with reference to the appended drawings, which are provided for guidance only and which are therefore non-limiting, in which:

[0075] FIG. 1 is a sectional schematic side view of equipment for moulding and curing tyres according to the present invention in a first operating position;

[0076] FIGS. 2 and 3 show enlargements of two details of the equipment of FIG. 1:

[0077] FIG. 2a shows the detail of FIG. 2 further simplified;

[0078] FIGS. 4a and 4b show, respectively, a perspective view and a partial view in lateral section of a lower bead moulding ring in a first operating position;

[0079] FIGS. 5a and 5b show, respectively, a perspective view and a partial view in lateral section of the lower bead moulding ring in a second operating position;

[0080] FIG. 6 shows a perspective view of an upper bead moulding ring in a first operating position;

[0081] FIG. 7 shows a perspective view of the upper bead moulding ring in a second operating position;

[0082] FIGS. 8 to 10 show views from above of further different preferred examples of embodiment of the lower and/or upper bead moulding ring in a first operating position;

[0083] FIGS. 11 to 13 show simplified sectional side views of three different preferred examples of a tyre according to the present invention;

[0084] FIGS. 14 to 20 show a plurality of steps of the method of controlling a phase of moulding an annular fixing structure of a green tyre, in which the moulding and curing equipment is depicted schematically, in lateral section, and only partially.

[0085] With reference to FIG. 1 initially, the number 100 indicates equipment for moulding and curing tyres for vehicle wheels according to the present invention.

[0086] The equipment 100 is capable of accommodating green tyres 50 assembled in a preceding manufacturing phase, or in a suitable building phase; for example, the green tyres 50 can be built from elementary components such as continuous elongate elements of elastomeric material, strip elements cut to size and containing at least two fabric or metal cords running parallel to each other, or rubberized fabric or metal cords deposited on a suitable forming support.

[0087] In detail, the green tyre 50, shown only in section and schematically in the appended FIG. 1, defines an axis X substantially coinciding with its own axis of rotation and comprises a carcass structure 52 including at least one carcass ply (not numbered in the drawings) which is associated for operation with a pair of annular fixing structures 51a and 51b, a tread band 53 in a position radially external to said carcass structure, and a belt structure (not shown) interposed between the carcass structure and the tread band 53.

[0088] As shown schematically in FIG. 1, the annular fixing structures 51a and 51b represent the two opposing ends of the green tyre 50.

[0089] The equipment 100 comprises a curing mould 200 which has a lower sidewall plate 20 and an upper sidewall plate 21 which are, respectively, engaged with a base 15 and with a closing portion 16 of a container 17, and a substantially cylindrical telescopic central body 3, with an axis Y, into which the green tyre 50 is inserted. The central body 3 is moved in its axial telescopic elongations and contractions by using hydraulic cylinders (not shown), for example.

[0090] The mould 200 also includes a ring of circumferential sectors 55 which define a mould cavity in which is defined a geometric axis which coincides with the axis Y of the central body 3 and which preferably also coincides, as shown in FIG. 1, with the axis of rotation X of the green tyre 50 when the latter is inserted into the equipment 100.

[0091] The circumferential sectors 55 generally carry forming projections (not shown in FIG. 1) and are designed to act on a radially outer surface of the tread band 53 of the green tyre 50, to create in this tread band a series of indentations and channels positioned suitably in a desired tread pattern.

[0092] To enable a single reference system to be used, the axial directions in the following text are directions parallel to the central body 3 and parallel to the axis of rotation X of the tyre inserted into the equipment 100. Similarly, a radial direction is the direction of a radius originating on the axis of rotation (perpendicular to it) of the tyre. In a similar way, internal and external, and terms related thereto, refer to the inner cavity of the equipment (described more fully below) and/or of the tyre.

[0093] The base 15 and the closing portion 16, together with the corresponding lower sidewall plate 20 and upper sidewall plate 21, are movable with respect to each other between an open condition in which they are remote from each other to permit the introduction of the green tyre 20 to be cured into the mould 200, and a closed position in which they are placed next to each other to enclose the green tyre 50 in the mould cavity (in other words, the container 17).

[0094] In detail, the sidewall plates 20 and 21 face each other and are designed to act, respectively, on the opposing annular fixing structures 51a and 51b of the green tyre 50, in order to shape its axially inner and outer surfaces, as described more fully below.

[0095] Preferably, with reference to the details shown in FIGS. 2, 3 and 2a, each of the sidewall plates 20, 21 has a perimetric supporting surface 31a, 31b, on a portion of which a respective portion of a radially inner and axially outer surface 7a, 7b of the annular fixing structures 51a, 51b bears.

[0096] Additionally, an expandable bladder 30 of toroidal shape, delimited by a membrane 31, is fixed to the telescopic central body 3, preferably at its two opposing ends. The bladder 30 can expanded during the moulding and curing process, so as to bring the membrane 31 into contact with the radially inner surface of the green tyre 50, thus pressing this surface outwards and supplying heat to it, and in this way exerting a moulding pressure and transmitting at least some of the heat required for curing.

[0097] The bladder 30 is inflated by using a feed device which introduces a fluid, such as steam, air or inert gases, through a suitable passage which is not shown in the drawings, until the desired moulding pressure is reached.

[0098] As shown more fully below, the expandable bladder 30 is also capable of exerting a pre-moulding pressure referred to hereafter as the second squeezing pressure, in order to bring the first and second annular fixing structures into contact with the upper and lower sidewall plates, so as to shape the radially inner and axially outer surface portion 7a, 7b of each annular fixing structure 51a, 51b by using the respective sidewall plate 20, 21, together with a radially inner and axially inner surface portion 8a, 8b of each annular fixing structure, as detailed below.

[0099] The reference numerals in FIG. 2a indicate the various surfaces to provide a clear identification of these with reference to the lower annular fixing structure 51a.

[0100] The equipment 100 also comprises a first plate 6 and a second plate 7 fixed to the two opposite ends of the central telescopic element 3. The equipment 100 also includes at least a first bead moulding ring 60a, and more preferably two bead moulding rings, namely an upper and a lower ring 60a, 60b, which are movable from a first contracted operating position to a second expanded operating position in which they form a contact surface 33a, 33b. In this second expanded operating position, with the green tyre 50 inserted in the mould 200, each ring 60a, 60b can come into contact with the first radially inner and axially inner surface portion 8a, 8b respectively of the first and the second annular fixing structures 51a, 51b of the green tyre 50. In the contracted position, the bead moulding rings 60a, 60b have a diameter smaller than the diameter of the green tyre 50 at the locations of the annular fixing structures 51a, 51b, thus enabling the tyre to be inserted into or removed from the central body 3.

[0101] Preferably, the lower and upper bead moulding rings 60a, 60b are fixed at the locations of the plates of the central body 3, and are concentric with this body (in other words, the axis Y passes through the centre of each ring).

[0102] The configuration of the equipment 100 at the location of the lower sidewall plate 20 is described more fully below, and this description, where no express indication to the contrary is given in the text, is preferably also to be interpreted as referring to the configuration of the equipment 100 at the location of the upper sidewall plate 21.

[0103] When the green tyre 50 is inserted into the mould 200 and the lower bead moulding ring 60a is in an expanded position, as stated above, the radially inner and axially outer surface portion 7a of the lower annular fixing structure 51a of the tyre bears against a portion of the supporting surface 31a belonging to the lower sidewall plate 20 of the mould, while the portion of the radially inner and axially inner surface 8a of the annular structure 51a bears against a surface portion 33a formed on the lower bead moulding ring 60a which also acts as a stop surface, the structure thus being clamped between the two opposing surfaces which exert a first squeezing pressure on the bead.

[0104] When the bladder 30 is expanded up to the second moulding pressure, the membrane 31 comes into contact with a second axially inner surface portion of the lower annular fixing structure 51a which is located in a radially outer position with respect to the area of contact between the annular fixing structure 51a and the lower bead moulding ring 60a (in other words, a radially outer position with respect to the first surface portion 8a), and which is contiguous to this area. The pressure exerted by the membrane 31 on the inner surface of the green tyre 50 as described more fully below enables the annular fixing structure 51a to be moulded accurately, since the membrane acts as a further stop surface for the annular structure, thus creating a specific shape of the radially inner and axially outer surface 7a and the radially inner and axially outer surface of the annular structure 51a.

[0105] FIGS. 2 and 3 show two enlarged details with the tyre 50 inserted and the bladder 30 expanded, and with the bead moulding rings 60a, 60b both in the expanded operating position of the equipment 100 at the locations of the lower sidewall plate 20 and the upper sidewall plate 21 respectively. As shown in FIG. 2, the lower annular fixing structure 51a is locked and delimited by a plurality of surfaces, in portions of both its radially inner and axially inner surface 8a and its radially inner and axially outer surface 7a; in other words, its radially inner and axially inner surface portion 8a is delimited by a portion of the circumferential surface 33a of the lower bead moulding ring 60a and by a portion of the membrane 31, while its radially inner and axially outer surface portion 7a is delimited by the perimetric surface 31a of the lower sidewall plate 20. FIG. 3, in which the letter a is replaced with b in the reference numerals of the above description, shows how the upper annular fixing structure 51b is also locked between two surfaces.

[0106] The lower bead moulding ring 60a is shown schematically in detail in FIGS. 4a, 4b and 5a, 5b. The ring includes a series of sectors divided into a first and a second plurality 8, 9, each sector of the first plurality 8 alternating circumferentially with a sector of the second plurality 9. The sectors of the first plurality 8 are radially divergent; in other words, as they depart from the axis Y of the mould 200 they have the shape of a segment whose edge 34 defines a radially outer circular sector which has a greater extension than a radially inner edge opposite thereto. The sectors of the second plurality 9 are radially convergent; in other words each of them is also shaped in the form of a segment, but an edge 34 defines a radially inner sector of a circle which has the greater extension of each segment as compared with a radially outer edge opposite thereto.

[0107] The ring 60a also includes an element 10 in the shape of a cone or a truncated cone positioned parallel to the axis Y of the mould 200, and having its vertex 11 inserted into the centre of the bead moulding ring 60a.

[0108] Additionally, the sectors 8, 9 can slide from a contracted operating position to an extended operating position. In the first contracted operating position, the edge 34 defining the radially outer circular sector of said first plurality 8 and the edge 34 defining the radially inner circular sector of said second plurality 9 are offset in said first contracted operating position of said first bead moulding ring 60a; in other words, the second plurality of convergent sectors 9 is more re-entrant (having a smaller distance between the circular sector 34 and the axis Y) than the first plurality 8 of divergent sectors.

[0109] The contracted operating position is reached when the cone-shaped element 10 is only partially inserted into the centre of the ring 60a and does not create any compression towards the plate 6 (see FIGS. 4b and 5b). When the cone-shaped element 10 moves towards the plate 6, this movement being provided by hydraulic cylinders for example, the first and second plurality of sectors 8, 9 are extended, by their downward translation and simultaneous radial movement. The second plurality of convergent sectors 9 is aligned with the first plurality of divergent sectors 8; in other words, the edge 34 of said first plurality of divergent sectors 8 is circumferentially aligned with a radially outer edge of said second plurality of convergent sectors 9 in said second extended operating position of the ring, thus forming a continuous circumferential surface 33a (see FIG. 5a).

[0110] Opposing springs 35 (visible in FIGS. 4b and 5b) ensure that the sectors 8, 9 contract when the cone-shaped element 10 is translated away from the plate 6, and that the diameter of the ring 60a is reduced.

[0111] With reference to FIGS. 6 and 7, the second bead moulding ring 60b comprises a plurality of petal-like elements 36 having substantially identical shapes to each other, said elements 36 being movable from a first contracted operating position in which they are partially superimposed to a second operating position in which they are contiguous. The movement from one operating position to the other takes place, for example, by a relative rotation of the elements 36 by using a driving cam on a splined shaft (not shown in the drawings).

[0112] In a different embodiment, the bead moulding ring 60a, 60b does not include a continuous contact surface 33a, 33b in the form of a circular ring, as described above, but, when expanded, it also includes various separated and non-contiguous sub-surfaces in this operating position. As shown in FIGS. 8, 9 and 10, the moulding ring 60a, 60a and 60a comprises 2, 3 or 4 sectors 8, 8, 8 respectively, but the number of sectors 8 can be determined at will, these sectors being movable, as stated above, from a contracted operating position to an expanded operating position. However, it is preferable for the angular extension of the separate sub-surfaces in a circumferential plane to form an angle greater than 18.

[0113] In order to move from one operating position to the other, it is possible, for example, to use the cone-shaped element 10 (not shown in FIGS. 8 to 10), which was described above with reference to FIGS. 6 and 7, in the bead moulding rims 60a, 60a, 60a of FIGS. 8-10.

[0114] Additionally, each surface or sub-surface of the bead moulding rings can be smooth (i.e. flat) or can be differently shaped, by including for example ribbing, knurling, alphanumeric characters, or the like, which will modify the finished tyre as described below.

[0115] Additionally, regardless of the shape of the contact surfaces of the moulding rings, the distance D shown in FIG. 2a, in other words the distance on a circumferential plane between the radially innermost end of the portion of the radially inner and axially inner surface 8a of the annular fixing structure 51a and the corresponding contact surface portion 33a of the bead moulding ring 60a, is preferably in the range from approximately 5 mm to approximately 40 mm, or more preferably in the range from approximately 7 mm to approximately 20 mm.

[0116] In a preferred embodiment, said elements 36 have a ribbed surface or a surface showing a pattern of any type only in the area in contact with the annular fixing structure of the green tyre 50.

[0117] According to the method of the invention, in a configuration with the dosing element 16 placed in the open position, with the inflatable bladder 30 in the deflated operating position, and with both of the bead moulding rings 60a, 60b contracted and therefore forming a diameter smaller than the diameter of the green tyre in a circumferential plane at the location of the annular fixing structure 51a, 51b, the green tyre 50 is positioned; for example by using a robotic arm using grippers, on the base 15 of the mould 200 in such a way that: it is fitted into the central body 3 and the axis of rotation X of the green tyre 50, and the axis Y of the equipment 100 coincide. In this configuration which is shown in FIG. 14, the lower annular fixing structure 51a of the green tyre bears against the lower sidewall plate 20. The bead moulding ring 60a is housed inside the green tyre 50.

[0118] As mentioned above, the central body 3 is preferably telescopic, so that its height can be adjusted to match green tyres 50 of various sizes. It is then translated in such a way that the second plate 7 carrying the second bead moulding ring 60b is brought to the location of the upper annular fixing structure 51b. The travel of the telescopic body 3 is predetermined according to the axial dimension of the tyre 50.

[0119] The lower and upper bead moulding rings 60a, 60b are then brought into the second expanded operating position, in which they form an extended contact surface 33a, 33b having a diameter greater than the diameter of the green tyre 50 at the location of the annular fixing structures 51a, 51b. The configuration reached in this step is shown in FIG. 15, in which each annular fixing structure 51a (51b) is delimited by two substantially opposed surfaces, in other words by the surface 31a (or 31b) of the sidewall plate 20 (21) and by the surface 33a (33b) of the bead moulding ring 60a (60b). This surface 33a (33b) can be in contact with the surface 8a (8b) of the bead 51a (51b) over a radial extension of 360 in the case in which it has the shape of a circumferential ring, or only at certain points, for a given radial extension according to the number of sectors 8, 8, 8 included in the bead moulding ring.

[0120] The bead moulding rings 60a, 60b are then translated towards the respective upper and lower sidewall plates 20, 21 so as to compress the two annular fixing structures 51a, 51b at a first squeezing pressure. As a result of this translation, each structure 51a, 51b comes into contact with and is correctly placed against the corresponding sidewall plate 20, 21, and the radially inner and axially inner surface portion 8a, 8b and the radially inner and axially outer surface portion 7a, 7b of each structure 51a, 51b are initially clamped and placed. The configuration reached in this step is shown in the sequence of FIGS. 16a and 16b, which show a detail of the moulding and curing equipment 100 on an enlarged scale. As mentioned above, the drawings show the annular fixing structure 51a (51b) locked and correctly brought into contact with the corresponding surfaces as a result of the translation of the bead moulding ring 60a (60b), and a first squeezing pressure is exerted on it as a result of the thrust of the ring towards the corresponding sidewall plate. This first pressure is preferably in the range from approximately 0.1 bar to approximately 5 bars. The aforesaid pressure is a specific pressure, in other words a pressure derived from the thrust provided by hydraulic cylinders, for example, on the bead moulding rings 60a, 60b.

[0121] The bladder 30 is then inflated (this step being shown in FIGS. 16c and 17) by introducing steam, hot air or other heated fluid or gas through a passage which is not shown in the drawings, in order to keep the green tyre 50 substantially locked around the central body 3 and to prevent undesired movements of the tyre.

[0122] Preferably, the equipment 100 is still open during the initial inflation of the bladder 30 (FIG. 17), and subsequently, when a minimum pressure of the bladder 30 is reached, the equipment according to the invention 100 is closed by using the closing element 16, in such a way that the upper annular fixing structure 51b of the green tyre 50 bears against the upper sidewall plate 21 (see FIG. 18). The bladder 30 is then inflated until the second squeezing pressure of the annular fixing structures 51a, 51b is reached, the structures being clamped between the sidewall plates and the bead moulding rings, as described below. Preferably, said second squeezing pressure, also called the pre-moulding pressure, is greater than 0.2 bar and equal to or less than approximately 8 bars.

[0123] By using the pressure exerted by the bladder 30, the bead moulding ring 60a, 60b is further translated towards the corresponding sidewall plate 20, 21 in such a way that a greater pressure is exerted on the annular fixing structures 51a, 51b and the radially inner and axially inner surfaces 8a, 8b and the radially inner and axially outer surfaces 7a, 7b are then shaped, by pre-moulding (FIG. 16c).

[0124] It should be emphasized that, in this description and in the subsequent claims, each value of pressure due to direct fluid pressure is to be interpreted as a relative value of pressure with respect to atmospheric pressure.

[0125] Preferably, the pressure exerted by the bladder 30 on the annular fixing structures 51a, 51b increases from a minimum and then rises in monotonic way until the moulding and curing pressure is reached. Alternatively, the pressure exerted by the bladder can rise substantially in a stepped way, in which the bladder is brought to the second squeezing pressure for a specified time interval. The second squeezing pressure is subsequently raised to the correct pressure for moulding and curing.

[0126] In this configuration, at the second squeezing pressure (FIG. 16c), a portion of the membrane 31 of the bladder 30 comes into contact with the second axially inner surface portion 8a, 8b of the lower and upper annular fixing structures 51a, 51b, thus pushing them outwards. As a result of the combined action of the bead moulding rings 60a, 60b, the sidewall plates 20, 21 and the membrane 31, the annular fixing structures 51a, 51b are shaped to the desired geometry.

[0127] In particular, the pressure exerted on each annular fixing structure 51a, 51b produces a modification of the shape with respect to the initial shape, in other words with respect to the shape of the green tyre 50 at the time of its insertion.

[0128] The expandable bladder 30 is kept at this second squeezing pressure for a period preferably in the range from approximately 2 to approximately 60 minutes, or more preferably from approximately 4 to approximately 40 minutes.

[0129] The fluid present in the expandable bladder 30 while the second pressure is exerted has a temperature preferably in the range from approximately 140 C. to approximately 210 C.

[0130] At the end of the period required for the pre-moulding operation, the expandable bladder 30 is raised to a higher pressure, in other words the moulding pressure, generally in the range from approximately 16 bars to approximately 28 bars, for the purpose of moulding and curing the green tyre 50.

[0131] At the end of the moulding and curing step, the bladder 30 is deflated and the equipment 100 is opened. The lower moulding ring 60a is brought to the contracted operating position, thus releasing the lower annular fixing structure 51a, and the central body 3 is translated, thus raising the tyre (FIG. 19). Subsequently, when the upper moulding ring 60b is contracted, the finished tyre 50 is removed and placed, for example, on a discharge roller conveyor 25 (FIG. 20).

[0132] A new green tyre 50 is fitted in the equipment 100, and the cycle described above by way of example is repeated,

[0133] The finished tyre 50 has a specific shape of the annular fixing structures 51a, 51b, and in particular it has a specific shape of the radially inner and axially inner surfaces 8a, 8b, as shown in FIGS. 11 to 13, in which three different examples of embodiment of the aforementioned surfaces are shown schematically in cross section. In the drawings, only the surface 8a is indicated by a reference numeral, but identical details can be applied to the shape of the surface 8b.

[0134] In a first embodiment, in which the bead moulding rings in the expanded operating position form a contact surface 33a, 33b which is substantially in the form of a circular ring and flat, as in the preferred example of FIGS. 6 and 7, the corresponding surface of the annular fixing structure 8a, 8b is also flat, continuous, smooth and/or polished, as shown in cross section in FIG. 11.

[0135] In the case (not shown) in which this contact surface 33a, 33b is again shaped in the form of a continuous circular ring, but has a rough surface rather than a ribbed surface or one including alphanumeric characters, the same structure is reproduced on the surface 8a, 8b, with a positive/negative moulding effect.

[0136] On the other hand, in the case in which, as shown in the bead moulding rings of FIGS. 8-10, the contact surface 33a, 33b comprises a plurality of sub-surfaces which are separate even in the extended operating position, the resulting surface 8a, 8b of the annular fixing structure 51a, 51b also has an undulating structure as shown in cross section in FIG. 12, the number n of undulations depending on the number n of sub-surfaces included in the bead moulding ring.