TYRE MANUFACTURE

Abstract: A tread package (11, 12) etc. for a tyre is assembled within a pattern ring (6) and a pattern imparted to the tyre tread. The tread is at least partially cured in the ring (6). When the package is assembled with other tyre components the complete green cover, but with a partially cured tread rubber, is moulded and cured in a mould devoid of any means for imparting a pattern to the tread.

Description: "TYRE M AN UFACTURE" This invention relates to tyre manufacture. Conventional methods of tyre manufacture comprise assembling a "green cover" from a plurality of unvulcanised rubber components, placing the green cover into a mould and applying heat and pressure so that the final shape, particularly the tread pattern, is imparted to the covers and the rubber cured, so that a complete tyre is formed. The stages of moulding and curing the tyre are expensive because a large, steam heated press working on a heating cycle of about 15 minutes, for a size of tyre suitable for a car, is required. The press is conventionally designed to accom modate two tyre oulds so two tyres are produced simultaneously but the moulds themselves are expensive particularly because they each comprise a large number, e.g. up to 64, tread moulding seg ents m ounted in a backing ring. Each individual segment is made from die-cast alu minium alloy and machined to a complex shape so is therefore expensive. The other parts of the mould for shaping the tyre side walls, etc. are also expensive. Not only are the moulds expensive but they are only capable of being used to form one size of tyre. For example it is not possible to allow a range of tyres with different tread widths to be for ed in the same mould. It is an object of the present invention to attempt to overcome or alleviate these disadvantages. In accordance with the present invention a method of manufacturing a tyre comprises assembling an annular tread package which includes uncured rubber into a pattern ring to impart a pattern to the tread rubber, heating the tread rubber to become at least partially cured, positioning the remaining components of the tyre within the annular tread package either before or after the pattern ring is heated, separating the pattern ring from the tread rubber, placing the assembled tyre within a mould which contains no means to impart a pattern to the tread rubber and heating the mould completely to cure the tyre. The tread package may comprise tread rubber, sub- tread (or under- tread) rubber, a breaker comprising one or more layers of rubberised cord fabric, a breaker cushion and fill T strips. Not all these components may be present depending on the type of tyre being manufactured. The pattern ring ay be heated to cause at least partial curing of the tread rubber, and depending on the temperature and length of time for which the ring is heated, to cause at least partial curing of the remaining rubber in the package a veneer of rubber on the radially inner side of the package is preferably partially or wholly uncured so as to facilitate adhesion to the remaining parts of the tyre, particularly the tyre carcass, during subsequent assembly. The pattern ring preferably comprises a plurality of segments which may be moved radially inward or outward in a controlled manner, in particular outward movement causing the separation of the ring from the tread rubber at the appropriate stage of tyre manufacture. Two embodiments of the invention will now be described by way of example with reference to the accompanying drawings, in which: Figure 1 is a cross-section through a conventional tyre to be manufactured by the ethod according to the invention, Figure 2 is a cross-section through a tread package in a pattern Figure 2a is a diagram atic side view of the tread package and the pattern ring, Figure 3 is a cross-section through the tread package and the carcass in the pattern ring, and Figure 4 is a cross-section through the complete tyre in a mould. The tyre shown in Figure 1 comprises a tread package of tread and under- tread rubber 1, two breaker layers 11, 12 each of rubberised cord fabric and rubber filler strips 13, 14, a carcass comprising a carcass ply 3 extending between and being anchored around two bead cores 4 and 5 in conventional manner and two side walls 2, 21 each comprising a layer of rubber. In the method of the first embodiment the tread package is assembled by positioning the two filler strips 13, 14, the two breaker layers 11, 12, the under-tread rubber and the tread rubber in turn around a cylindrical mandrel. A pattern ring 6 (see Figure 2 and 2a) comprising a plurality of segments 7, 8, 9, 10 (in this embodiment four) s expanded by oving the segments radially outward and then closed in a controlled anner around the tread package on the mandrel, The segments are provided with ribs 15 and/or other projections etc. so as to impart the required pattern to the tread rubber. The ring is then heated to a predetermined temperature for a predetermined length of time, e.g. by steam or an electric current, so as to cause the rubber of the tread package to become partially cured. However a veneer of rubber on the radially inner surface of the radially inner breaker layer is deliberately left uncured, or only slightly cured. This assists the adhesion of the tread package to the carcass during a subsequent state in the tyre manufacture. The mandrel is then collapsed radially inwards leaving the tread package located in the closed pattern ring. The pattern ring 6 and the tread package 1 located therein are then positioned accurately around a conventional tyre building former on which a tyre carcass comprising a carcass ply 3 and beads including bead cores 4, 5, has been assembled in a conventional manner in a cylindrical shape. The former is then expanded to cause the carcass to be shaped to torc dal form and the crown of the carcass to be pressed into contact with the radially inner surface of the tread package 1, and in particular with the uncured, or only slightly cured, veneer on the radially inner breaker ply 12. The tyre sidewaUs 2, 21, i.e. layers of rubber to protect the carcass ply 3 in use of the tyre, may be applied to the carcass when it is in either the cylindrical or toroidal shape. The pattern ring 6 is then separated from the tread rubber by •5 expanding the segments 7, 8, 9 and 10 radially outward, the former collapsed, and the completed green cover, but comprising a partially cured tread package, placed in a mould 16 as shown in Figure 4. This mould is devoid of any means, e.g. ribs or other projections, to impart a pattern to the tread rubber, and may or may not shape the sidewalls, depending on 10 whether the sidewaUs were pre-shaped before being applied to the carcass. The ould, in a press, is then heated in conventional manner to complete the cure of the tyre. In the method of the second embodiment the tread package is assembled in the pattern ring 6, and the remaining parts of the tyre 15 assembled and shaped w fhin the tread package as described in the method of the first embodiment, but the tread package is not heated and therefore not cured at all until it is in contact with the carcass 3 as shown in Figure 3. However, by limiting the temperature of the pattern ring and the length, of time for which it is heated only the tread package and no 20 other part of the tyre becomes partially cured. It is an advantage of the second embodiment that since the radially outer surface of the carcass is brought into contact with the radially inner surface of the tread package adhesion is ensured. Both embodiments of the invention allow relatively high pressure 25 to be used during curing of the tread package, thus ensuring good homogeniety. Additionally it is believed that this improves the tread life of the finally cured tyre in use. Furthermore by imparting a pattern to the tread alone, and then partially curing it, more consistency in shape is obtained from one tyre to the next compared with conventional methods. Since in both embodiments of the invention the time for the pattern ring to impart a pattern to the tread ring is much shorter than the ti e taken for a complete tyre to be moulded and cured in a conventional mould the overall cost can be reduced. Furthermore since the mould is devoid of means to impart a pattern to the tread rubber by use of suitable inserts the same mould ay be used to cure tyres of different tread widths with a corresponding reduction in expenditure. Although the mould used in the method of the present invention is devoid of pattern-imparting means it may have one or more radially inward projections which, by locating in the pre-formed tread pattern, serve to locate the green cover accurately in the mould. A principal advantage of the method according to the present invention is that cure time in the final mould is substantially reduced.

Claims: AMENDED CLAIMS [received by the International Bureau on 30 March 1989 (30.03.89) ; original claim 1 amended; new claims 4, 7 and 8 added; claim 4 amended and renumbered as claim 5; claims 5-8 unchanged but renumbered as claims 6, 9 and 10; other claims unchanged ( 2 pages ) ] 1. A method of anufacturing a tyre comprising assembling an ann lar tread package which includes uncured rubber into a pattern ring to impart a pattern to the tread rubber, heating the tread rubber to become partially cured, portioning the remaining components of the tyre within the annular tread package either before or after the tread rubber is heated, separating the pattern ring from the tread rubber, placing the assembled tyre within a mould which contains no means to impart a pattern to the tread rubber and heating the mould completely to cure the tyre. 2. A method as claimed in claim 1, wherein the tread package is assembled on a mandrel before being assembled into the pattern ring. 3. A method as clai med in clai 1 or clai m 2, wherein the pattern ring is heated to cause the tread package to become at least partially cured. 4. A method as claimed in claim 3, wherein the tread package is cured under relatively high pressure. 5. A method as claimed in claim 3 or claim 4, wherein a veneer of rubber on the radially inner side of the package is partially or wholly uncured. 6. A method as clai med in any one of the preceding claims, wherein the pattern ring comprises a plurality of radialLy oveabLe segments which are moved radially outwards in a controlled manner to separate the ring from the tread rubber. 7. A method as claimed in any one of the preceding claims, wherein the mould is capable of being adapted to cure, one at a time, tyres of more than one size. 8. A method as claimed in any one of the preceding claims, wherein the mould is capable of imparting a pattern to the sides of the assembled tyre during curing. 9. A method of manufacturing a tyre substantially as described herein particularly with reference to Figure 2 and Figure 4 of the accompanying drawings. 10. A method of manufacturing a tyre substantially as described herein with particular reference to Figure 3 and Figure 4 of the accompanying drawings. 11. A pneumatic tyre manufactured by the method claimed in any one of the preceding claims.

Inventors: GOODFELLOW ANTHONY GERALD, HOLROYD COLIN, GOODFELLOW, ANTHONY, GERALD, HOLROYD, COLIN
Applicants: HOLROYD ASSOCIATES LTD, HOLROYD ASSOCIATES LIMITED
Application year: 1988
Main classification: B29D30
IPC codes: B29C33, B29D30, B29K105, B29L30