Improved pneumatic tyre construction and manufacturing method

Abstract: A pneumatic tyre comprising a ground contacting tread comprising a tread strip (1) extending axially between tread edges (2) and sidewalls (3) extending radially inwardly from each tread edge (2) to respective bead regions (4), the tread being reinforced by at least a first circumferentially extending breaker ply (8), characterised in that each sidewall (4) is reinforced by a carcass half ply (5) extending from a radially inward first edge (6) in the bead region (4) to a radially outward second edge (7) in the tread axially between the centre and adjacent edge (16) of the breaker ply (8), the carcass half ply (5) comprising one or more reinforcing elements (14) wound continuously between the radially inner and outer edges (6,7) of the carcass half ply (5) and around the circumferential periphery of the tyre.

Description: This invention relates to a pneumatic tyre and particularly but not exclusively to a radial tyre and provides a construction improved in materials usage and a manufacturing method improved in cost efficiency. Conventional pneumatic tyres have a reinforced carcass extending between two wheelrim contacting bead regions through sidewall regions and a ground contacting tread region. Inflation pressure within the cavity formed by mounting the tyre onto the wheelrim tensions the carcass and thus provides the primary load support mechanism. In a modern radial tyre construction the carcass is reinforced by a ply of tyre fabric comprising radially or substantially radially orientated cords which extend through the carcass continuously from one bead region to the other through the sidewalls and tread. These carcass cords are anchored in each bead region by being folded around an inextensible circumferentially extending bead core or hoop to form ply turn-up portions. Furthermore in the tread region of the conventional radial tyre the ground contacting rubber tread strip is also reinforced by a substantially inextensible belt or breaker taking the form of a cylindrical band. The belt or breaker is disposed radially outward and adjacent to the carcass ply and inward of the rubber tread strip and any tread pattern formed therein. This belt or breaker has substantially the same axial width as the tyre tread and functions to keep the tread flat on the road surface. Breakers conventionally comprise plural plies of tyre fabric having parallel cords which are inclined to the tyre circumferential direction and crossed with respect to the cords of adjacent plies. Breaker plies may comprise organic cords or glass fibres but are usually steel cords. In tyres of the older so-called "crossply" construction the carcass comprises usually two or more plies having cords inclined to the tyre circumferential direction and crossed with respect to the cords of adjacent carcass plies. Such crossply tyres may also be fitted with breakers in the tread in a so-called 'bias belted' tyres. Thus is became clear to the Inventor of the present application in studying general aspects of tyre construction that a substantial proportion of tyres have a surfeit of reinforcement in certain regions and particularly tyres which benefit from the presence of a belt or breaker in the tread strip have a more than adequate level of total reinforcement in the tread region. DE 2 064 753 according to which the preamble of claim 1 is established, discloses a tyre with two half-carcasses comprising reinforcing elements wound continuously and zigzag between the radially inner and outer edges of the carcass half ply and around the circumferential periphery of the tyre. The radially inner ends of the carcass half plies are turned up around the bead cores. US 3,451,461 discloses a similar tyre, and DE 36 31 736 A1 discloses a tyre having a single carcass without turned-up portions. It is therefore an object of the present invention to provide a tyre having an improved utilisation of materials in the construction of the carcass. A further object of the invention is to provide a method of manufacturing the tyre of the invention which is more cost efficient. The first object is achieved by the features of claim 1, and the second object is achieved by the features of claims 10. Further aspects of the invention will become apparent from the following description by way of example only of one embodiment in conjunction with the following schematic drawings in which: Figure 1 shows a radial cross-section of one half of a tyre in accordance with the invention; Figure 2 shows an isometric view of the assembly of some of the components of the tyre on a tyre building former; and Figures 3 and 4 are schematic diagrams showing the zigzag winding of reinforcing elements located in the tyre sidewall. The tyre shown in Figure 1 has a tread region comprising a ground contacting tread strip 1 extending between tread edges 2. Sidewalls 3 extend radially inwardly from each tread edge 2 to bead regions 4. On the radially inner surface of the tyre there is a rubber innerliner 10 comprising a low air-permeability compound to provide retention of the inflation medium. The tread region of the tyre is reinforced between the tread edges 2 by a breaker comprising two centrally disposed breaker plies 8 and 9. The radially outer breaker ply 9 has a width BW2 greater than the width BW1 of the inner breaker ply 8. Each of the breaker plies 8 and 9 comprises parallel steel cords inclined at an angle of 18°-22° to the tyre circumferential direction. The cords of breaker ply 8 are crossed with respect to those of adjacent breaker ply 9. The breaker is disposed radially inward of the tread strip and the tread pattern formed therein which is represented in Figure 1 by tread grooves G1-G3. In accordance with the invention each of the sidewalls 3 of the tyre is reinforced by a carcass half-ply 5 which extends between a radially inward first edge 6 in the bead region 4 and a radially outer second edge 7 in the tread region. In the tread region, the radially outward second edge 7 of the carcass half-ply 5 is disposed radially between the breaker plies 8 and 9. The half-ply 5 overlaps the axially outer part of the narrower inner first breaker ply 8 on its radially outer side by a distance Wo equal in this embodiment to 20% and preferably between 15% and 35% of the width BW1 of the narrower first breaker ply 8. As can be seen the radially outer end portion of the carcass half-ply 5 is disposed between the inner and outer breaker plies 8 and 9 and is thus even more securely fixed into the tread reinforcing breaker. As is common in the art a breaker cushion rubber 11 may be disposed radially inward of the axial outer portion of the widest breaker ply 9 to support the breaker ply and separate it from carcass half-ply 5. At the radially inward end of the carcass half-ply 5 is securec in the bead region 4 by virtue of being held between axially inner and outer bead cores 12 and 13 respectively which each comprise a circumferentially extending inextensible hoop comprising a bundle of one or more bead wires 15. The bead wires 15 may comprise any common in the art such as single strand wire, twisted wires or multifilaments in the form of cables. It should be noted that in the tyre of Figure 1 there is no conventional carcass turn-up portion. As can be seen in Figure 2 each carcass half-ply 5 comprises one or more reinforcing elements 14 wound continuously between the radially inner and outer edges 6 and 7 and around the circumferential periphery of the tyre sidewall. Preferably the reinforcing elements are cords which may be formed from those materials common in the art such as steel or textile including glass fibres or organic fibres such as nylon, rayon, polyester or aramid. Also preferably the reinforcing elements are coated or embedded in rubber to form a tape in which the reinforcing elements extend longitudinally. Most preferably a narrow tape comprising a single reinforcing element is used. In this embodiment the reinforcing element or elements as shown in Figures 2 and 3 are wound zigzag between the edges such that they lie substantially radially . However they may be wound zigzag at an angle to the radial direction as shown in Figure 4 or they may be woven or knotted together between the edges. The configuration of the carcass half-plies in the bead and tread regions permits the carcass reinforcement to adopt a natural position prior to vulcanisation in the mould. This aids the elimination of localised stress areas in the carcass resulting in a reduction in non-uniformities within the tyre giving improved ride comfort. Where the reinforcing elements 14 are disposed zigzag between the half-ply edges 6 and 7 it is preferred to form each half-ply at the time of building or assembling the tyre components into the uncured or green tyre carcass by winding the reinforcing element or elements formed into a tape directly onto the rubber innerliner 10 on the tyre building former F as shown in Figure 2. However what ever form the carcass half-ply reinforcement takes, the half-plies may if preferred be formed in a separate operation prior to the assembly of the green carcass on the building former F. The tyre of the present invention may also be provided with a breaker cover ply radially outward of the breaker according to service requirement. This cover ply may comprise a single or plural wrap of a substantially full width ply or alternatively a so-called "jointless bandage" construction. According to the above-described embodiment the present invention provides a tyre and a method of manufacturing a green tyre carcass which eliminates non-essential materials in the tread and bead regions and which therefore represents improved utilisation of materials, reduced tyre weight and more cost efficient manufacture. The method of construction is also capable of aiding automation of the tyre manufacturing process by forming the main carcass reinforcing, i.e. the carcass half-plies at the time of component assembly using a suitable machine to wind the reinforcement between the first and second edges.

Claims: A pneumatic tyre comprising a ground contacting tread comprising a tread strip (1) extending axially between tread edges (2) and sidewalls (3) extending radially inwardly from each tread edge (2) to respective bead regions (4), the tread being reinforced by at least a first circumferentially extending breaker ply (8), wherein each sidewall (4) is reinforced by a carcass half ply (5) extending from a radially inward first edge (6) in the bead region (4) to a radially outward second edge (7) in the tread axially between the centre and adjacent edge (16) of the breaker ply (8), the carcass half ply (5) comprising one or more reinforcing elements (14) wound continuously and zigzag between the radially inner and outer edges (6,7) of the carcass half ply (5) and around the circumferential periphery of the tyre, characterised in that in the region of the radially inner first edge (6) the carcass half-ply abuts a circumferentially extending inner bead core (12) disposed within the bead region (4) axially inward of the carcass half-ply (5) and a circumferentially extending outer bead core (13) disposed within the bead region (4) axially outward of the carcass half-ply (5) and in that the tread strip is reinforced by a second breaker ply (9). A tyre in accordance with claim 1, characterised in that the one or more reinforcing elements (14) of the carcass half-plies (5) are disposed substantially radially. A tyre in accordance with claim 1 or 2, characterised in that the carcass half-plies (5) comprise a single reinforcing element. A tyre according to any of claims 1 to 3, characterised in that each carcass half-ply (5) overlaps the radially outer side of the first breaker ply (8). A tyre according to any of claims 1 to 4, characterised in that the second breaker ply (9) is radially outward of the first breaker ply (8). A tyre in accordance with claim 5, characterised in that the second breaker ply (9) overlies the radially outer edges (7) of the two carcass half plies (5). A tyre in accordance with claim 6, characterised in that the axial width (BW2) of the second breaker ply (9) is greater than the axial width (BW1) of the first breaker ply (8). A tyre in accordance with any of claims 1 to 7, characterised in that the carcass half plies (5) overlap the narrowest breaker ply (8) by between 15 and 35% of the axial width (BW1) of the narrowest breaker ply (8). A tyre in accordance with any of claims 1 to 8, characterised in that the one or more continuous reinforcing elements comprise rubber coated tyre cords. A method of building an uncured tyre according to any of the preceding claims on a tyre building former (F) comprising assembling onto the former a first breaker ply (8) in the former central region and two inner bead cores (12) in each of the former axial edge regions, subsequently forming two carcass half-plies radially outward of the breaker ply and bead cores by winding one or more continuous reinforcing elements (14) zigzag between a first edge (6) axially outward of the inner bead core (12) and a second edge (7) axially between the breaker ply centreline and the adjacent breaker ply edge (16) and assembling onto the former a second breaker ply (9) in the former central region and two outer bead cores (13) in each of the former axial edge regions.

Inventors: FYFE ERIC THOMAS WATSON, FYFE, ERIC THOMAS WATSON
Applicants: SUMITOMO RUBBER IND, SUMITOMO RUBBER INDUSTRIES LIMITED
Application year: 1998
Main classification: B60C9
IPC codes: B29D30, B60C9, B60C15