TYRE AND METHOD FOR MAKING A TYRE

Abstract

A tyre (1), comprising: two toroidal bead portions (12), each housing an annular bead bundle (121); a toroidal body ply (10), folded, at each of its transversal ending portions (101), about a respective bead bundle (121) forming a respective turn-up (14); two bead fillers (20), one for each bead portion, each in contact with a respective bead bundle (121) and at least partly enclosed by a respective turn-up (14),

which tyre (1) further comprises two elastomeric crack control members (21), one for each bead portion (12), wherein each crack control member (21) extends at a body ply ending (101), externally to the respective turn-up (14), and each crack control member (21) is made by a couple of strips having a differentiated stiffness along their transversal section, with a lower stiffness at a first strip (201, 211) adjacent to the body ply ending (101) and a higher stiffness at a second strip (202, 212) in contact with the respective bundle (121),

so that the first lower stiffness strip defines a preferential propagation path for any tyre crack originating at the body ply folded ending (FIG. 2).

Claims

1.-17. (canceled)

18. A tyre, comprising: two toroidal bead portions, each of said two toroidal bead portions housing an annular bead bundle and having an external abrasion gum strip; a toroidal body ply, which is folded, at each one of two transversal endings thereof, about a respective annular bead bundle forming a respective turn-up; two bead fillers, one for each of said two toroidal bead portions, each of said two bead fillers being in contact with a respective bead bundle and being at least partly enclosed by a respective turn-up of said toroidal body ply, wherein the tyre further comprises two crack control members, one for each of said two toroidal bead portions, wherein each crack control member of said two crack control members extends at a body ply ending axially externally to the respective turn-up, each crack control member having a differentiated stiffness along its transversal section, with a lower stiffness at a first portion adjacent to said body ply ending and a higher stiffness at a second portion remote from said body ply ending and adjacent a respective abrasion gum strip, the configuration being such that said first portion defines a preferential propagation path for any tyre crack originating at said body ply ending, characterized in that each of said crack control members is obtained as a part of, and/or is integral to, the respective bead filler.

19. The tyre according to claim 18, wherein each bead filler is obtained from one or more strips interposed between the respective bead bundle and the body ply and wound about the bead bundle according to a U or annular shape internally to the respective turn-up.

20. The tyre according to claim 19, wherein one or more strips of each bead filler have an outer end folded into a U about the respective body ply ending and out of the corresponding turn-up so as to enclose such body ply ending by forming a cap around it and making at least part of the respective crack control member.

21. The tyre according to claim 20, wherein each bead filler is made from a first, low-stiffness strip arranged in contact with said body ply and a second, high-stiffness strip having a higher stiffness than said first strip and arranged in contact with the respective bead filler, wherein each of said first and second strip makes a respective first or second portion of said crack control member.

22. The tyre according to claim 21, wherein each of said first and second strips is wound about the bead bundle according to a U or annular shape internally to the respective turn-up.

23. The tyre according to claim 22, wherein said first strip extends only at, or at a part of, a transverse terminal end of said body ply ending.

24. The tyre according to claim 18, wherein said first portion of said crack control member has a stiffness of about M502.5 Mpa and ELB 400% and/or said second portion of said crack control member has a stiffness M50 comprised in a range of about 2.0-11.0 MPa and ELB comprised in a range of about 80%-400%.

25. The tyre according to claim 18, wherein, before vulcanization, said first portion of said crack control member has a thickness comprised in a range of about 0.2-1.5 mm and/or said second portion of said crack control member has a thickness comprised in a range of about 0.2-1.5 mm or 0.5-2.5 mm.

26. The tyre according to claim 18, which is a tyre for a passenger vehicle.

27. A method for making a tyre, comprising the following steps: lying a body ply about a construction drum; lying two bead fillers, each substantially in form of one strip or of more strips superimposed one to the other, onto the body ply, in such a way that a portion of each of said two bead fillers makes a crack control member that extends transversely beyond a respective body ply ending; positioning two bead bundles, each onto a respective bead filler; turning-up transversal ending portions of the body ply and of the one or more strips of the respective bead fillers about the respective bead bundles, so as to form two lateral turn-ups, each of which encloses at least partly a bead bundle; and vulcanizing tyre bead portions, wherein, at any time before or after said turning-up, each of said crack control members is folded about the respective body ply ending so as to extend externally along such body ply ending as a cap, and wherein each of said crack control members has a differentiated stiffness along its transversal section, with a lower stiffness at a portion adjacent the body ply and a higher stiffness at a portion adjacent a respective abrasion gum strip.

28. The method according to claim 27, wherein said turning-up carries two opposed portions of each bead filler in close proximity or contact one to the other, so that such portions connect at said vulcanizing step.

29. The method according to claim 27, wherein, at said turning-up step, any air entrapped in the structure is eliminated.

30. The method according to claim 27, wherein said step of lying the bead fillers comprises arranging two strips one superimposed to the other and each making a respective lower or higher stiffness portion of said crack control member.

31. The method according to the claim 30, wherein the one of said strips having lower stiffness is laid onto the body ply and extends only at a transverse terminal end of the body ply ending.

32. The method according to claim 27, wherein said step of lying the bead fillers onto the body ply takes place only after said step of lying the body ply onto the construction drum.

33. The method according to claim 27, wherein said step of positioning the bead bundles onto said bead fillers takes place only after said step of lying the bead fillers onto the body ply.

34. The method according to claim 27, which is a method of making the tyre according to claim 1.

35. The tyre according to claim 18, wherein said two crack control members are made of elastomer.

36. The tyre according to claim 19, wherein each bead filler is obtained from one or more strips of elastomeric material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Reference will be made to the figures of the enclosed drawings, wherein:

[0037] FIG. 1, already introduced above with reference to the state of the art, shows a schematic cross-sectional view of a known tyre, only some parts of which have been exemplified;

[0038] FIG. 2 shows a schematic cross-sectional view of a first preferred embodiment of the tyre according to the present invention, of which, for greater clarity, only a half-section has been represented;

[0039] FIG. 2A shows an enlarged detail of FIG. 2, in particular relating to a portion of the tyre bead of this latter figure;

[0040] FIG. 3 shows a schematic cross-sectional view of a second preferred embodiment of the tyre according to the present invention, of which, also in this case for greater clarity, only a half-section has been represented;

[0041] FIG. 3A shows an enlarged detail of FIG. 3, relating in particular to a portion of the tyre bead of this latter figure;

[0042] FIGS. 4A, 4B and 4C each show a schematic cross-sectional view referring to a respective construction step of the tyre shown in FIG. 2, whereinfor greater claritysome parts of both a tyre construction apparatus and the tyre have not been represented;

[0043] FIGS. 5A, 5B and 5C each show a schematic cross-sectional view referring to a respective construction step of the of the tyre shown in FIG. 3, whereinalso in this case for greater claritysome parts of both a tyre construction apparatus and the tyre have not been represented;

[0044] FIGS. 6 and 7 show, schematically and by way of example, the path of a crack possibly originated in the tyre according to FIG. 2 and FIG. 3, respectively.

[0045] The thicknesses and curvatures shown in the figures introduced above are to be understood as purely exemplary and are not necessarily shown in proportion. Moreover, as said, in said figures some layers/components of the tyre and of its construction apparatus may have been omitted, for a clearer illustration of aspects of the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0046] Hereinafter several embodiments and variations of the invention will be described, with reference to the figures introduced above.

[0047] Analogous components in different figures are denoted by the same reference number.

[0048] In the detailed description that follows, further embodiments and variants with respect to embodiments and variants already treated in the description will be illustrated only in conjunction with the differences with respect to what has already been exposed.

[0049] Moreover, the different embodiments and variants described in the following are possibly employed in combination, when they are compatible.

[0050] With reference initially to FIGS. 2 and 2A, a tyre according to a first preferred embodiment of the invention is generally denoted by 1. Preferably, the tyre 1 is a low turn-up tyre, in particular it is a RDP tyre.

[0051] Since tyre 1 is represented in half-section, in the following reference will be made to the elements and components present in the represented part. It will be understood that what is described also applies to the part contralateral to that shown.

[0052] Similarly to what already described in conjunction with the known art, tyre 1 comprises, in its outer part, a toroidal tread 2 and two side walls arranged, in use, in a position respectively distal and proximal to the vehicle. In FIG. 2 the proximal side, denoted by 3, is visible. Bilaterally to tread 2, between it and each sidewall, two respective transition areas (shoulders) are provided, one of which is shown in FIG. 2 and denoted by 4. Still at the outer part, in the portion close to/in contact with the rimalso here denoted by Ctyre 1 has Abrasion Gum Strips (AGS), one of which is shown in FIG. 2 and denoted by 5.

[0053] The tyre main body, i.e. the carcass, is denoted by 6.

[0054] Inside the tyre, between tread 2 and carcass 6, a body ply 10 having a toroidal configuration is interposed. Also in the present case, a tread belt 11 separates body ply 10 from tread 2.

[0055] Tyre 1 also comprises two toroidal portions intended to engage the rim C, i.e. two beads, one of which is visible in FIG. 2 and denoted by 12.

[0056] An annular bundle of metal cords (bead bundle), generally enclosed in a case made of elastomer, is inserted within bead 12. Such bundle, together with its casing, is denoted by 121.

[0057] A bead filler, overall denoted by 20, is associated with bead bundle 121.

[0058] At bead 12, body ply 10 is folded about the bead bundle 121 and respective filler 20, so as to form a respective turn-up 14. The end portion of the body ply part that makes turn-up 14 is denoted by 101 and its terminal end by 102 (body ply ending or point P1 mentioned with reference to the prior art). The body ply part making turn-up 14 defines a compartment having a substantially triangular geometry. Said compartment has a base on the side of the rim and an apex on the side of tread 2. Bead bundle 121 is arranged adjacent to the base and it is in contact with filler 20 at filler portions remote from the apex.

[0059] As shown in greater detail in FIG. 2A, bead filler 20 has a portion 21 which comes out from turn-up 14 and which is turned up itself externally to body ply end portion 101. Such portion 21, for reasons that will clarified later on, is herein called a crack control element. Therefore, crack control element 21 extends externally to turn-up 14, developing adjacently to body ply end portion 101. The crack control element length is represented by way of example in the figures considered herein.

[0060] Crack control element 21 has a differentiated stiffness along its transverse section. For this purpose, it comprises a first portion 211 adjacent to body ply 10 and a second portion 212 distal (or remote) from body ply 10, which second portion 212 is therefore directed towards the outside of tyre 1 on the side of abrasion gum strip 5. First portion 211 is less stiff (softer) than second portion 212 (the latter being harder).

[0061] Crack control element 21 is typically made of elastomer. In the present example, it is made of two elastomeric materials of different stiffness, coupled during construction of tyre 1 according to modes that will be explained shortly.

[0062] Preferably, second portion 212 has a stiffness greater than that of the adjacent abrasion gum strip 5.

[0063] For example, first portion 211 may have a stiffness M50about 2.5 MPa, preferably M50about 2.2 MPa, and ELBabout 400%, preferably of about 500%, wherein ELB indicates the Elongation at Break and M50 the stiffness modulus at 50% elongation.

[0064] Second portion 212 may have stiffness M50 comprised in a range of about 2.0-11.0 MPa and ELB may be comprised in a range of about 80%-400%, preferably M50 is comprised in a range of about 6.0-11.0 MPa and ELB is comprised in a range of about 80%-160%.

[0065] The abrasion gum strip may have stiffness M50 comprised in a range of about 1.0-2.0 MPa and ELB may be comprised in a range of about 300%-400%, preferably M50 is comprised in a range of about 1.5 to 2.0 MPa and ELB is comprised in a range of about 335-365%.

[0066] With regard to thicknesses (before a vulcanizing step), exemplary values are indicated below.

[0067] For first portion 211, the thickness is preferably comprised in a range of about 0.2-1.5 mm.

[0068] For second portion 212, the thickness is preferably comprised in a range of about 0.2-1.5 mm.

[0069] As will be illustrated in detail also in the following, first portion 211 of member 21 provides a preferential path for the propagation of any crack originating at body ply ending 102 and, in general, at body ply end portion 101.

[0070] In consequence of the described configuration, abrasion gum strip 5 may have a thickness comprised in a range of about 2.0-7.5 mm, measured at a radial distance below point P1 of about 5 mm.

[0071] The structure of bead filler 20 and of its crack control member 21 can be better understood by referring to the construction modes of tyre 1, schematically illustrated in the sequence of FIGS. 4A to 4C. Also in this case reference will be made, for simplicity of explanation, to the construction of bead portion 12 only, it being understood that the other bead is made contextually in the same construction apparatus and according to the same operations/steps of the construction method.

[0072] Referring initially to FIG. 4A, first of all body ply 10 is laid onto a construction drum 400, represented in a very schematic way. The bead filler, in form of a pair of strips 201 and 202, is laid onto body ply 10. Strips 201 and 202 correspond to portions 211 and 212, respectively, and make such portions downstream of a final vulcanizing step of tyre 1 which will be considered shortly.

[0073] The transversal outer part of strips 201 and 202 makes crack control member 21. Such part extends beyond end 102 of body ply 10 and it is folded, or better turned up, beyond the latterthat in this step or in a subsequent step. Said filler turning up prevents the formation of air sacs generated during tyre construction.

[0074] Bead bundle 121 is then placed onto second strip 202.

[0075] Preferably, for the purpose of precise positioning, body ply 10 is arranged on drum 400, then first strip 201 is arranged onto body ply 10; similarly, after the placement of the first strip onto body ply 10, second strip 202 is laid onto first strip 201; still, bead bundle 121 is laid onto second strip 202 after having laid the latter onto first strip 201.

[0076] At this point, as shown in FIG. 4B and 4C, drum components can be actuated, in particular two bladders 401 and 402, which fold into a U body ply 10 and filler about bundle 121, until the two filler branches of the U come into contact.

[0077] In the preferred embodiment considered herein, the configurationand in particular the total length and positioning of the filler stripsis such that the filler results interposed between turn-up 14 and the contra-lateral flap of body ply 10 facing the tyre inside, i.e. the axially inner and descendant part of body ply 10. In other words, in the present configuration the two contralateral flaps of body ply 10 are not in direct contact in turn-up 14. In particular, in the described configuration the filler turn up at its crack control member 21 makes at least this filler part is always interposed between end 102 of body ply 10 and its contra-lateral side. Such interposition, single or double, of filler 20 between opposite flaps of body ply 10 facilitates, downstream of a vulcanizing step, a mutual adherence of the components, in particular preventing the detachment of the flaps of body ply 10.

[0078] As mentioned, a step of vulcanizing bead 12 follows, simultaneously to the vulcanizing of further parts of tyre 1. Such vulcanizing makes the material of original strips 201 and 202 fill completely the inner space of turn-up 14, eliminating any local air sacs. Equally, vulcanizing makes crack control member 21 adhere externally to body ply 10.

[0079] As said, each strip 201, 202 corresponds to a respective portion 211, 212 of crack control member 21, respectively of lower and higher stiffness. In the present example, therefore, the differential stiffness is provided also at the filler portion which properly performs a filling function, i.e. which is arranged within turn-up 14.

[0080] It will be understood that even though some tyre components, in particular filler 20, have been defined and denoted by the same reference number before and after the vulcanizing step, they, upstream and downstream of such step, may have different properties, for example a different configuration, conformation and thickness.

[0081] Furthermore, the above description does not mention, for reasons of brevity, the application of other elements of the tyresuch as the so-called inner liner and the abrasion gum stripsbecause such application may be accomplished by known modes.

[0082] It will be understood that said tyre vulcanizing step takes place at the end of the construction process, after all components have been assembled.

[0083] FIGS. 3 and 3A show a different embodiment of a tyre according to the invention, here denoted by 100. In tyre 100, the crack control member, denoted by 210, comprises a first portion 221 of lower stiffness which extends only at body ply ending 102 of body ply 10 and from it towards the outside of the tyre. In particular, first portion 221 defines a sort of cap for ending 102 of body ply 10.

[0084] Crack control member 210 further comprises a second portion 222, similar to second portion 212 described with reference to the first embodiment. In this case, second portion 222 may have a thickness greater than the first embodiment. Preferably, in this embodiment, the thickness of the second portion 222 (before vulcanizing) is comprised in a range of about 0.5-2.5 mm.

[0085] In this second embodiment, therefore, the bead filler, denoted by 220, is made almost completely by second portion 222, first portion 221 contributing only to a small part of such filler 220 in proximity of body ply ending.

[0086] Also in this case, bead filler 220 and crack control member 210 can be made starting from a pair of strips of suitable arrangement and configuration. The modes for making a tyre are is schematically illustrated in the sequence of FIGS. 5A to 5C.

[0087] Propagation patterns of a possible crack inside tyres 1 and 100 are shown in FIGS. 6 and 7, respectively.

[0088] In particular, the crack, starting from body ply ending 102 of body ply 10, finds a stiffness (deformability) gradient at the interface between first portion 211, 221 and second portion 212, 222 of crack control member 21, 210. Consequently, on the basis of behaviors known from fracture mechanics, said crack propagates according to a preferential path, that we may define radial, within portion of lower stiffness 211, 221. After the crack has overcome the extension of crack control member 21, 221, it propagates axially towards abrasive gum strip strip 5, reaching the outside of tyre 1, 100.

[0089] Therefore, it will be better understood that tyre durability is greatly increased compared to a crack propagation exclusively axial.

[0090] Some simulations have been carried out upon tyre virtual models, in order to assess the deformation distribution under stress in the area denoted by X in FIGS. 6 and 7, for the two preferred embodiments considered here. Such area X corresponds to an interface region between body ply 10, crack control member 21, 210 and abrasive gum strip 5.

[0091] Such simulations have shown that deformation of body ply 10 in the concerned area is more limited compared to that of known solutions. This circumstance reduces the risk of crack generation.

[0092] Furthermore, the deformation of portion 211, 221 of lower stiffness is high, while that of the stiffer portion 212, 222 is very low, resulting in a reduced risk of direct propagation of the crack into abrasive gum strip 5.

[0093] At this point, it will be better appreciated that the invention allows obtaining the (additional) advantages described below.

[0094] First, the tyre construction method is simpler, because the strips/portions constituting the filler of each bead (and the associated crack control member) can be simply laid one onto the other upon the body ply before the turn-up operation. Therefore, it is no longer necessary to pre-couple together the bead filler and the respective bead bundle, which is a rather delicate operation required in the known tyres.

[0095] In the preferred embodiments with two strips considered above, the tyre construction is cheaper than that of solutions adopting localized reinforcements in addition to the bead filler, because of both the lowest cost of the individual elements and the simplification of the construction method, which requires no separate steps of preparation and assembly of the bead filler and the reinforcements.

[0096] Furthermore, tyre construction is more effective and efficient because the strips/portions, pre-assembled onto the body ply in the manner described above, are tightened onto the body ply during the subsequent body construction, thus eliminating any air sacs and/or risks of micro-defects.

[0097] Still in the preferred embodiments with two strips considered above, the stiffest strip compresses the less stiff strip against the body ply, further reducing the risk of manufacturing defects and the formation of air sacs.

[0098] The present invention has been up to here described with reference to preferred embodiments. It is to be intended that other embodiments are possible within the same inventive core, as defined by the scope of protection of the following claims.