Heavy duty radial tyre

Abstract: A heavy duty radial tyre for a 15 degree taper centre drop rim having improved bead durability is disclosed. The tyre comprises a pair of bead cores (5) disposed one in each bead portion (4), a steel cord radial carcass ply turned up around the bead cores (5) from the axially inside to the outside, a hard rubber bead apex (11) disposed between the carcass ply main portion and each turnup portion, a bead filler (10) of reinforcing cords disposed axially outside each carcass ply turnup portion (6B), and a rubber strip (9) disposed between each turnup portion and the bead filler, the rubber strip being harder than the bead apex (11), and the difference B-D of the inside diameter B of the bead cores from the rim diameter D of the rim is in the range of from -4 to 1 mm.

Description: The present invention relates to a heavy duty radial tyre for a 15 degree taper centre drop rim and more particularly to an improved bead structure capable of preventing carcass ply separation failure and then to improve bead durability. In general, heavy duty radial tyres such as truck/bus tyres used under high-pressure and heavy-load conditions are provided with a steel cord carcass ply which is turned up around bead cores. These tyres are used together with a 15 degree taper centre drop rim (for example, R06-1 in JATMA) in which the rim base (bead seat) is tapered at 15 degrees to provide a large inter-engaging force between the and rim. Heavy duty tyres are often used under a severe condition such that the tyre deflection reaches to 15 % of the tyre section height. Under such a severe condition, stress is liable to concentrate on the cord ends of the carcass turnup portion, and thus a separation failure from the surrounding rubber is liable to occur. In such a heavy duty radial tyre, the angle of the carcass cords is substantially 90 degrees to the tyre equator, which is regarded as a cause of the concentration of deformation because it is difficult for the carcass to lean circumferentially of the tyre and also toward the rim flange. Hitherto, therefore, as shown in Figs.6 and 7, the bead portions of a heavy duty radial tyre are provided with a steel cord bead filler (d) extending along the carcass turnup portion (c1) to increase the rigidity and thus to decrease deformation. The cords of the bead filler (d) are inclined circumferentially of the tyre for example at an angle of not more than 60 degrees to the circumferential direction of the tyre to lean easily not only toward the rim flange (j1) but also circumferentially of the tyre. In Fig.6, the bead filler (d) is lower in height than the outer end (ct) of the turnup portion (c1) of the carcass (c) in order to reduce the deformation of the tyre during rolling which is transmitted to the tread, belt, carcass main portion (c2), bead apex (e) and carcass turnup portion (c1). The bead filler supports the outside of the carcass turnup portion (c1) against the deformation to prevent the separation between the cord ends of the turnup portion (c1) and rubber. In Fig.7, the bead filler (d) is higher in height than the outer end (ct) of the carcass turnup portion (c1). In this case, the deformation of the tyre during rolling is transmitted to the tread, belt, carcass main portion (c2), bead apex (e) and then the bead filler (d) before the carcass turnup portion (c1). Thus, the bead filler further reduces the deformation around the outer end (ct). As explained above and in US 5,196,077, it has been known to be effective for reinforcing the bead portion of a heavy duty pneumatic tyre to dispose such bead fillers in the bead portion. However, the present inventors discovered that it is also possible to improve the durability of the bead portion by decreasing the difference B-D of the inside diameter (B) of the bead core (f) of the tyre from the rim diameter (D) of a 15 degree taper centre drop rim. Here, the inside diameter (B) is of the tyre when not mounted on the rim as shown in Fig.6. In a conventional heavy duty tyre with a steel cord carcass (c) reinforced by a bead filler (d) extending from the radially inside of a bead core (f) toward the radially outside, as the rigidity of the bead portion is very high, the difference B-D between the inside diameter (B) of the bead core and the rim diameter (D) is set at a relatively large value of for example not less than 2 mm, giving priority to the rim mounting. However, if the diameter difference B-D is too large, the tyre bead base (g) has a tendency to move axially outwardly along the rim seat (h) when the tyre is inflated, and the so called rotation stress of the carcass ply around the bead core (f) increases and the deformation of the bead portion increases. Further, the bead compression between the bead core (f) and the rim seat (h) decreases, which involves problems of carcass ply slipping-out, carcass ply turnup looseness and the like. On the other hand, the rubber thickness between the carcass cords and the bead filler cords, measured at the bead filler end (dt) in Fig.6 and the carcass turnup end (ct) in Fig.7, is usually set at a very small value of under 1.0 mm. Thus, in spite of the provision of the bead filler (d), a stress concentration occurs on the ends (dt) in Fig.6 and (ct) in Fig.7, and as a result, a separation failure (PTL: Ply Turnup Looseness) starting from these ends is liable to be caused. Therefore, a primary object of the present invention is to provide a heavy duty pneumatic tyre in which the bead durability is effectively improved. Another object of the present invention is to mitigate the stress liable to concentrate on the outer end of the carcass turnup portion or the bead filler which is lower than the other to prevent the ply separation and thus to improve the bead durability. Accordingly the present invention comprises a heavy duty radial tyre as set out in claim 1. By setting the diameter difference B-D at a considerably small value, the bead deformation is decreased, and the bead compression is increased. As a result, carcass ply slipping-out, carcass ply turnup looseness and the like can be prevented. Preferably, the carcass consists of a single ply, the bead filler consists of a single ply of steel cords, and a rubber strip is disposed between each turnup portion and the bead filler, wherein the rubber strip extends at least from a point between each turnup portion and the bead filler to a radially outer end of the turnup portion or the bead filler which is higher than the other, and the rubber strip has a thickness such that the distance between the carcass cords and the steel bead filler cords measured at a radially outer end of the turnup portion or the bead filler which is lower than the other is in the range of from 2.5 to 5.0 times the diameter of the carcass cords. By setting the distance wider than the conventional range, depending on the carcass cord diameter, the stress concentration on the cord ends can be mitigated, to prevent ply separation failure and the bead durability is further improved. Further, the JIS-A hardness of the rubber strip is preferably set in the range of from 70 to 90 degrees and larger than the JIS-A hardness of the bead apex by not less than 10 degrees. When the carcass is composed of a plurality of plies and/or the bead filler is composed of a plurality of plies, the radially outermost end (highest end) is used for the radially outer end of the carcass turnup portion and the radially outer end of the bead filler. Embodiments of the present invention will now be described in detail in conjunction with the accompanying drawings. Fig.1 is a cross sectional view of an embodiment of the present invention; Fig.2 is a cross sectional view of the bead portion thereof showing an example of the bead structure; Fig.3 is an enlarged partial view Figure 2; Fig.4 is a cross sectional view of another example of the bead portion according to the present invention; Fig.5(a) and Fig.5(b) are schematic cross sectional views explaining the position for the end 10E of the bead filler; and Figs.6 and 7 are schematic cross sectional views of the conventional bead portions. In Fig.1, the heavy duty radial tyre according to the present invention is a truck/bus tyre, and is shown mounted on its standard rim J (that is a 15 degree taper centre drop rim) and inflated to standard inner pressure. The tyre comprises a tread portion 2, a pair of sidewall portions 3, a pair of bead portions 4 each with a bead core 5 therein, a carcass 6 extending between the bead portions, and a belt 7 disposed radially outside the carcass 6 and inside the tread portion 2. Further, each bead portion 4 is provided with a bead apex 11, a chafer 14 and a bead filler 10 to reinforce this portion. The carcass 6 comprises at least one ply of steel cords arranged radially at an angle of 90 to 80 degrees with respect to the tyre equator and extending between the bead portions and turned up around the bead cores 5 from the axially inside to the outside thereof to form a pair of turnup portions 6B and one main portion 6A therebetween. In this embodiment, the carcass 6 consists of a single ply of steel cords arranged at substantially 90 degrees to the tyre equator. The radially outer end 6T of the turnup portion 6B is set at a relatively low height such that its height h3 from the bead base line BL (corresponding to the rim diameter) is 1.0 to 4.0 times, more preferably 1.6 to 3.0 times the flange height (rh) of the 15 degree taper centre drop rim J, so the tyre has a so called low turnup structure. If the turnup height h3 is less than 1.0 times the flange height (rh), the turnup portion 6B is liable to slip or pull out of the bead portion towards the main portion 6A. If the height h3 is more than 4.0 times the flange height (rh), the turnup end 6T approaches the sidewall region 3 where the bending deformation is largest and thus- ply turnup looseness is liable to occur near the outer end 6T. Further, the tyre weight increases. Generally, the flange height (rh) of the 15 degree taper centre drop rims is 12.7 mm. The belt 7 comprises at least two crossed plies of parallel steel cords, in this embodiment, four plies of steel cords. For example, the radially innermost first ply 7A is composed of rubberised steel cords laid in parallel with each other at an angle of 60 +/-10 degrees with respect to the tyre equator C. Similarly, the radially outer second, third and fourth plies 7B, 7C and 7D are each composed of steel cords laid at a small angle of from 15 to 30 degrees with respect to the tyre equator C. The bead core 5 is composed of windings of a steel wire. In order to withstand severe conditions and display a tight or strong hoop effect, the cross sectional shape of the bead core shown in Figs.1,2 and 4 is a flat hexagon of which a relatively long bottom side 5i becomes substantially parallel to the rim base J1 when mounted. However, it is also possible to use other cross sectional shapes, for example a circle as shown in Fig.5(b). The bead apex 11 is made of a hard rubber compound preferably having a JIS-A hardness A2 of 50 to 70 degrees, and disposed between the carcass main portion 6A and each turnup portion 6B. It tapers radially outwardly from the radially outer side of the bead core 5. It is also possible to use a bead apex made of two or more compounds having different hardnesses. The chafer 14 extends along the bead base 4A and the axially outer surface of the bead portion to protect the bead portion 4 from rim chafing. The chafer 14 is made of a relatively hard rubber compound having a JIS-A hardness of from 70 to 90 degrees. The bead filler 10 is composed of at least one ply, in this embodiment a single ply, of parallel steel cords 13 disposed axially outside the carcass turnup portion 6B. The steel cords 13 in each ply are inclined in the same direction at an angle of 15 to 60 degrees, in this example 25 degrees, with respect to the circumferential direction of the , whereby, the bead filler can lean axially and circumferentially of the tyre. In view of bead durability, rim mounting and tyre weight, it is preferable that the bead filler 10 is composed of a single ply of steel cords. However, the bead filler 10 can be composed of a single ply of organic fibre cords, and further two or more plies of steel cords, organic fibre cords, or a combination of steel and organic fibre cords. In Fig.2, the bead filler 10 extends radially outwardly beyond the radially outer end 6T of the carcass turnup portion 6B. In Fig.4, however, the bead filler 10 terminates under the radially outer end 6T of the carcass turnup portion 6B. The absolute value of the difference |h2-h3| between the height h2 of the radially outer end 10T of the bead filler 10 and the height h3 of the radially outer end 6T of the carcass turnup portion 6B, both measured from the bead base line BL, is preferably set in the range of from 5 to 25 mm. If the difference |h2-h3| is under 5 mm, the ends of the bead filler 10 and the carcass turnup portion 6B approach each other, and a stress concentrates on this part and a damage is liable to occur. If the difference is over 25 mm, the effect to reduce the deformation can not increase any more. This limitation is applied to both of the cases in which the height h3 is less than the height h2 as shown in Fig.2, and in which the height h3 is more than the height h2 as shown in Fig.4. In the later case shown in Fig.4, especially, the effect to reduce the deformation near the outer end 6T becomes insufficient when the difference |h2-h3| is over 25 mm. Further, the bead filler 10 extends radially inwardly to a position radially inward of the bead core 5 to be secured under the bead core. Therefore, in case of the above-mentioned flat hexagonal bead core, as shown in Fig.5(a), it is necessary that a part of the bead filler 10 is located in the region Q between the bottom 5i of the bead core and the bead base 4A. For the dimensional and positional accuracy of the bead filler 10 and the durability of the bead portion, preferably the radially inner end 10E of the bead filler 10 is disposed axially inwards of the axial centre line CL of the bead core 5. Further, in case of the bead core 5 having a circular cross sectional shape, as shown in Fig.5(b), it is necessary that the bead filler extends axially inwardly beyond an inner point 5C of the bead core at which the distance L between the bead core 5 and the bead base 4A is minimum. Furthermore, in the case of Fig.2, the radially inner end 10E of the bead filler 10 is disposed at a position under the bead core 5 slightly beyond the centre line CL of the bead core. In the case of Fig.4, the bead filler 10 extends axially inwardly through the radially inside of the bead core 5 and then radially outwardly along the axially inside of the carcass main portion, and the axially inner end 10E thereof reaches to a relatively higher position almost equal to the carcass turnup end 6T. Accordingly, the bead filler 10 is secured under the bead core 5 by an improved bead compression, and overlaps the carcass turnup portion 6B by a certain width 12. Thus, owing to the overlap portion 12, it becomes possible to reduce the deformation around the outer end 6T of the carcass turnup portion. Further, the difference B-D between the rim diameter D of the 15 degree taper centre drop rim and the inside diameter B of the bead cores 5 is set in the range of from -4 to 1 mm. Here, the inside diameter B is defined as of the radially inner extreme end of the bead core 5 when the tyre is not mounted on the rim. The rim diameter D accords with the definition for 15 degree taper centre drop rims specified in standard, e.g. JATMA, ETRTO, TRA and the like and thus well known in the art. As the difference B-D is very small in comparison with the conventional value of at least 2 mm, the bead deformation caused by the tyre inflation can be reduced, and further the bead compression is increased. Therefore, carcass ply slipping-out or pull out and ply turnup looseness can be prevented. By setting the difference B-D in the range of from -4 to 0 mm, remarkably -4 to -2 mm, the bead compression is further increased and the bead durability is further improved. If the difference B-D is under -4 mm,. the rim mounting operation has a tendency to become difficult. In view of this, the difference is set in the range of -2 to 1 mm, more preferably 0 to 1 mm. If much importance should be attached to the total balance, the difference B-D can be set in the range of from -2 to 0.5 mm. In both the examples shown in Figs.2 and 4, each bead portion is further provided with a rubber strip 9 between the carcass turnup portion 6B and the bead filler 10. The rubber strip 9 is made of a hard rubber compound having a JIS-A hardness A1 of from 70 to 90 degrees, more preferably 80 to 90 degrees. It is preferable that the difference A1-A2 of the JIS-A hardness A1 of the strip 9 from the JIS-A hardness A2 of the bead apex is not less than 10 degrees, more preferably not less than 15 degrees, but not more than 20 degrees. The rubber strip 9 extends at least from a higher outer end MT of the carcass turnup portion 6B or the bead filler 10 which is higher than the other to the lower outer end 12T other than the higher end MT. That is, the higher outer end MT is the bead filler end 10T in case of Fig.2, but the turnup end 6T in Fig.4. Accordingly, the lower outer end 12T is the turnup end 6T in Fig.2, but the bead filler end 10T in case of Fig.4. Preferably, the rubber strip 9 further extends radially outwardly beyond the higher outer end MT and radially inwardly beyond the lower outer end 12T, while tapering towards its radially inner and outer ends. The difference (a) between the height h1 of the radially outer end of the rubber strip 9 and that of the higher outer end MT is preferably in the range of from 0.25 to 1.0 times the height of the higher outer end MT (that is, h2 in Fig.2, and h3 in Fig.4), each height being measured radially from the bead base line BL. If the height h1 is not more than that of the higher outer end MT, a great difference in modulus from the rubber disposed radially outside the rubber strip 9 is formed, and bead filler ply looseness is liable to occur. Further, the radially inner end of the rubber strip 9 is preferably positioned sideways of the bead core 5, and/or the height h4 thereof is set in the range of not more than 80 % of the height of the lower outer end 12T (that is, h3 in Fig.2, and h2 in Fig.4) to avoid the occurrence of a large rigidity difference. The thickness of the rubber strip 9 is designed such that the distance (b) between the carcass cords 15 and the bead filler steel cords 13 measured at the lower outer end 12T (6T in Figs.2, and 10T in Fig.4) along the shortest path is preferably set in the range of from 2.5 to 5.0 times the carcass cord diameter K. As the minimum distance (b) is set depending on the carcass cord diameter K or the carcass cord rigidity, the stress concentration caused around the carcass cord ends can be mitigated to prevent the turnup portion 6B from separating, and thus the bead durability is further improved. If the distance (b) is less than 2.5 times the carcass cord diameter K, the share between the carcass cords 15 and the bead filler cords 13 is liable to increase. If the distance (b) is more than the carcass cord diameter K, the heat generation from the bead portion increases. Further, the rim mounting becomes poor and the tyre weight increases. In the example shown in Fig.2, the rubber strip 9 is provided on the axially outer surface with a step difference in level by which the axially outer surface of the bead filler 10 has the same level as the axially outer surface of a radially outer part of the rubber strip 9 as shown in Fig.3, whereby the higher outer end 10T is almost covered by the rubber strip 9 to prevent the cord ends from separating. The rubber strip 9 has a maximum thickness at a middle point immediately radially outside the higher outer end 10T, and the thickness gradually decreases radially inwardly and outwardly therefrom. In the example shown in Fig.4, the rubber strip 9 is provided on the axially inner surface with a step difference in level by which the axially inner surface of the carcass turnup portion 6B has the same level as the axially inner surface of a radially outer part of the rubber strip 9, whereby the higher outer end 6T is almost covered by the rubber strip 9 to prevent the cord ends from separating. Similarly to the Fig.2 example, the rubber strip 9 has a maximum thickness at a middle point immediately radially outside the higher outer end 6T, and the thickness gradually decreases radially inwardly and outwardly therefrom. In order that the rubber strip 9 functions correctly together with the bead apex 11, the thickness of the bead apex 11 is preferably designed to satisfy the following condition: the thickness (t1) measured at the higher outer end MT is 0.3 to 0.8 times the thickness (t2) measured immediately outside the bead core 5: and the height h5 of the bead apex is more than the height h1 of the rubber strip 9. Further, according to such arrangements, the above-mentioned rubber chafer 14 is preferably formed such that the tapered radially outer end thereof has a height h6 of more than the height h3 of the carcass turnup portion 6B, and more than the height h1 of the rubber strip 9, but less than the height h5 of the bead apex 11. Comparison Tests Test tyres of 11R22.5 16PR in size for truck and bus use were made by way of test. In the test tyres, the carcass was composed of a single ply of steel cords, the cord structure was 3/0.20+7/0.23, and the cord angle was 90 degrees to the tyre equator. The belt was composed of four plies of steel cords, the cord structure was 1X3/0.20+6/0.35, and the cord angles to the tyre equator and inclining directions were 67 degrees right, 18 degrees right, 18 degrees right, and 18 degrees left, in the order from the radially inside to the outside. The bead filler was composed of a single ply of steel cords, the cord structure was 3/0.17+7/0.20, and the cord angle was 25 degrees to the tyre equator. other specifications are given in Table 1. Each test tyre was tested for bead durability and rim mounting operation as follows. 1) Durability test Using a tyre drum tester, the test tyre was continuously run under the following accelerated conditions until visible damage occurred on the outside of the bead portion, and the running distance was measured. Running speed 20km/h load 300% of the maximum load (9000 kgf) Inner pressure Normal pressure of 8.00 kgf/sq.cm Wheel rim 22.5X8.25 standard rim (15 degree taper centre drop rim) In Table 1, the running distance is indicated by an index based on that Ref.1 tyre is 100, where the larger value is better. 2) Rim mounting test The time required to mount each test tyre on the standard rim by hand was measured. To minimise the error, the average value of five persons' times was used in this evaluation. In Table 1, the meanings of the symbols A, B, C and D are as follows: A: Time <.5 minutes B: 5 < Time ≤ 10 minutes C: 10 < Time ≤ 20 minutes D: It was impossible to mount the tyre by one person. Through the tests, it was confirmed that the tyres according to the invention are improved in the bead durability. Further, it was found that the best value for B-D is 0.5 mm, the best range for b/K is 2.5 to 3.4, the best range for A1-A2 is 10 to 15 degrees.

Claims: A heavy duty radial tyre to be mounted on a 15 degree centre drop rim comprising a pair of bead portions (4) each with a bead core (5) therein, a radial carcass ply (6) made of steel cords extending between the bead portions (4) and turned up around the bead cores (5) from the axially inside to the outside to form a pair of turnup portions (6B) and a main portion (6A) therebetween, a hard rubber bead apex (11) disposed between the main portion (6A) and each turnup portion (6B) and extending radially outwardly from the bead core (5), a bead filler (10) comprising a ply of reinforcing cords (13) disposed axially outside each turnup portion (6B) and extending radially outwardly from a position radially inwards of the bead core (5), characterised in that the difference B-D of the inside diameter B of the bead cores (5) from the rim diameter D of the rim is in the range of from -4 to 1 mm, and a rubber strip (9) is disposed between each turnup portion (6B) and the bead filler (10), the rubber strip (9) extending at least from a point between each turnup portion (6B) and the bead filler (10) to a radially outer end of the turnup portion or the bead filler whichever is higher than the other, and the rubber strip (9) having a thickness such that the minimum distance (b) between the carcass cords and the steel bead filler cords measured at a radially outer end of the turnup portion or the bead filler which is lower than the other is in the range of from 2.5 to 5.0 times the diameter (K) of the carcass cords. A heavy duty radial tyre according to claim 1, characterised in that the carcass (6) consists of a single ply and the bead filler (10) consists of a single ply of steel cords (13). A heavy duty radial tyre according to claim 1 or 2, characterised in that the JIS-A hardness of the rubber strip (9) is 70 to 90 degrees, and larger than the JIS-A hardness of the bead apex (11) by not less than 10 degrees.

Inventors: MIYAZAKI TATSUYA, UEYOKO KIYOSHI, MIYAZAKI, TATSUYA, UEYOKO, KIYOSHI
Applicants: SUMITOMO RUBBER IND, SUMITOMO RUBBER INDUSTRIES LIMITED
Application year: 1997
Main classification: B60C15
IPC codes: B60C15