Improvements to tyres

Abstract: A pneumatic tubeless tyre comprising a carcass ply (1) of reinforcing cords extending between two tyre bead regions (2) through sidewall regions (3) and a tread region (4) and an innerliner (6) disposed radially inwardly of the carcass ply (1), characterised in that in each tyre shoulder region (7) which is between the sidewall region (3) and the tread region (4) there is a circumferentially extending ply support strip (8) disposed radially between the carcass ply and the innerliner (6), the ply support strip (8) comprising a rubber compound containing short discontinuous fibrillated aramid fibres (31) in an amount of between 7 and 15 parts by weight per 100 parts by weight of rubber.

Description: The present invention relates to pneumatic tyres and particularly tubeless pneumatic tyres comprising a carcass of cord reinforced rubber fabric. The invention is particularly but not exclusively applicable to radial tyres in which the carcass cords extend radially between two bead regions. Conventional pneumatic tyres have a carcass comprising one or more plies of tyre fabric consisting of a plurality of parallel reinforcing cords embedded into a thin film or sheet of rubber. In modern radial tyres the carcass comprises one or more plies having cords in a radial configuration, whereas in older cross-ply constructions two or more plies of tyre fabric have their cords disposed at an angle to the radial direction and in crossing relationship to the cords of adjacent plies. Materials suitable for cords of tyres are varied and include organic materials such as rayon, nylon, polyester or aramid, inorganic materials such as glass or metals such as steel. Whichever material is used for the cord the tyre manufacturer endeavours to maximise the structural integrity of the tyre throughout its life by embedding the cords in suitable rubber compound known as a topping rubber which is particularly formulated to give good adhesion to material of the cord. The carcass of a tubeless pneumatic tyre is characterised by a rubber innerliner which is provided on the inside of the tyre surface radially inwardly of the carcass ply for the purpose of retaining the inflation medium when the tyre is mounted on a wheelrim. Accordingly the innerliner conventionally comprises a compound of a rubber which has low permeability to air, such as butyl rubbers or halo-butyl rubbers including bromo-butyl and chlorobutyl rubbers. The formulation of innerliner rubbers is directed towards maximising impermeability to air and the resultant compounds have little or no adhesion to the materials of tyre cords. The manufacture of a tyre commonly comprises a three-stage process. In the first stage the uncured rubber components of the carcass are laid sequentially around the outer surface of a drum to form a right-cylindrical assembly. This assembly includes a fabric of reinforcing cords which are laid over a thin sheet of rubber liner and anchored in each of the two edge regions of the cylinder which will ultimately form the bead regions of the tyres. In radial tyre manufacture the carcass ply cords extend perpendicularly between the edges of the right-cylindrical assembly. In the second stage of manufacture the first stage right-cylindrical assembly is deformed into a toroidal shape by radially outwardly expanding the central portion of the cylinder whilst simultaneously moving the edge portions nearer to each other. The remaining components of the tread region are then assembled onto the crown of the toroid to complete assembly of the uncured tyre. In the final stage of manufacture the uncured tyre is placed within a heated profile mould and given further slight radial expansion to form the tread pattern and finally vulcanise the tyre assembly transforming it from a plastic to an elastomeric state. A common problem which can arise in tyre manufacture concerns the length of the cord path between the edges of the right-cylindrical carcass assembly in the first stage of manufacture. If this length is too short, or if the cord path length or cord extensibility varies significantly around the periphery of the cylinder then during the above-mentioned subsequent expansion of the carcass the cords may tighten excessively such that the rubber material radially inward of the cords is pushed outward through the spaces between adjacent cords. Thus effectively the carcass cords are "pulled through" their cord topping rubber into the rubber below. In a radial tyre carcass this cord "pull through" is apt to occur locally in the tyre shoulder region beneath and outward of the breaker edge where the carcass curvature increases most rapidly. In extreme cases the carcass cords may pull all the way through to the interior surface of the tyre at which occurrence the tyre is scrapped on routine visual examination. However potentially more serious are cases where the carcass cords pull through to a lesser extent only into the rubber liner. Such occurrences may well not be evident on visual inspection of the tyre but the lack of adhesion between the carcass cords and the rubber poses a severe risk of subsequent premature failure of the tyre carcass in service. GB 2 096 949 A discloses a pneumatic radial tire comprising a carcass composed of one or more rubberized plies each containing cords arranged in radial planes, an inner liner rubber and a belt. To prevent a crack due to the large repetitive bending of the shoulder region, a rubber strip is arranged between the carcass and the inner liner rubber at each side of the tire in the shoulder region of the belt. EP 0 535 938 A1 discloses a pneumatic radial tire with a carcass layer composed of a single ply of carcass cords to reduce the tyre weight. To ensure a sufficiently high lateral spring constant, the tyre is provided with a rubber layer between a main carcass body and the turnups of the carcass layer at the bead cores. The rubber layer may include a fibre reinforcement of short fibres. It is an object of the present invention to prevent the phenomenon of carcass cord "pull through". This object is achieved by the features of independent claim 1. Further aspects of the present invention will become apparent from the following description by way of example only of one embodiment in conjunction with the following schematic diagrams in which: Figure 1 shows a cross-section of one half of a tyre of the invention; and Figure 2 shows the alignment of short discontinuous fibres in a ply support strip. The tyre depicted in Figure 1 is a tubeless radial tyre having a carcass ply 1 of cords extending radially between bead regions 2 through sidewall regions 3 and across a tread region 4. In each bead region the carcass ply of cords is anchored by being turned axially outwardly around a circumferentially extending inextensible bead core 5. The tread region 4 is reinforced across its width by a circumferentially extending breaker 5 disposed radially outwardly adjacent to the carcass ply 1. On the inner side of the carcass ply there is a rubber innerliner 6 comprising a compound of a low permeability halo-butyl rubber. In the shoulder region 7 of the tyre disposed between the carcass ply 1 the innerliner 6 is a ply support strip 8. This ply support strip 8 has a radial thickness t within the range of 0.5 to 1.5mm and in this embodiment is 0.8mm, and a width w measured along the carcass ply of between 15 and 75mm, again in this embodiment 35mm. The ply support strip 8 comprises a compound of by weight 100 parts natural rubber, 40 parts carbon black and 10 parts of discontinuous discrete fibrillated aramid fibres. To facilitate preparation of the compound the aramid fibres are used in a commercially available form of a predispersion of 23% by weight of fibres in natural rubber which is marketed by EI Du Pont de Nemours as one of the "KEVLAR® M/B" elastomer masterbatch range of materials. Whilst the fibrillated aramid fibres may be orientated randomly within the ply support strip 8 it is very much preferred to align them longitudinally in a direction substantially perpendicular to the longitudinal direction of the carcass reinforcing cords. Thus in the present embodiment the fibrillated aramid fibres are aligned within the ply support strip 8 in the tyre circumferential direction. The ply support strip 8 may be prepared by either lengthwise calendering or extrusion both of which subject the material to shear conditions which tend to orientate the aramid fibres 31 in the preferred longitudinal alignment as shown schematically in Figure 2. Whilst the ply support strip of the present embodiment comprises 10 parts by weight of fibrillated aramid fibres the amount may vary from 7 to 15 parts per hundred parts by weight of rubber. It has been found that if the amount of fibrillated fibres is less than 7 parts then the ply support strip has insufficient reinforcement to properly prevent cord pull through whilst amounts in excess of 15 parts render the strip excessively stiff.

Claims: A pneumatic tubeless tyre comprising a carcass ply (1) of reinforcing cords extending between two tyre bead regions (2) through sidewall regions (3) and a tread region (4) and an innerliner (6) disposed radially inwardly of the carcass ply (1), in each tyre shoulder region (7) which is between the sidewall region (3) and the tread region (4) a circumferentially extending ply support strip (8) being disposed radially between the carcass ply and the innerliner (6), the ply support strip (8) comprising a rubber compound, characterised in that the rubber compound contains short discontinuous fibrillated aramid fibres (31) in an amount of between 7 and 15 parts by weight per 100 parts by weight of rubber which are aligned longitudinally substantially perpendicularly to the direction of radial thickness (t) of the ply support strip. A pneumatic tubeless tyre according to claim 1, characterised in that the short discontinuous fibrillated aramid fibres (31) of the ply support strip (8) are aligned longitudinally in substantially the same direction. A pneumatic tubeless tyre according to claim 2, characterised in that the short fibres (31) are aligned perpendicularly to the reinforcing cords of the adjacent carcass ply (1). A pneumatic tubeless tyre according to any of claims 1 to 3, characterised in that the reinforcing cords of the carcass ply (1) extend substantially radially. A pneumatic tubeless tyre according to claim 4, characterised in that the short fibres (31) are longitudinally aligned in the tyre circumferential direction. A pneumatic tubeless tyre according to any of claims 1 to 5, characterised in that the ply support strip (8) contains short discontinuous fibrillated aramid fibres in an amount of 10 parts by weight per 100 parts of rubber. A pneumatic tubeless tyre according to any of claims 1 to 6, characterised in that the ply support strip (8) has a thickness (t) in the radial direction in the range of 0.5mm to 1.5mm. A pneumatic tubeless tyre according to any of claims 1 to 7, characterised in that the ply support strip (8) has a width (w) measured perpendicularly to the circumferential direction of the tyre in the range of 15mm to 75mm

Inventors: APPLETON PETER RAYMOND, APPLETON, PETER RAYMOND
Applicants: SUMITOMO RUBBER IND, SUMITOMO RUBBER INDUSTRIES LTD.
Application year: 1999
Main classification: B60C9
IPC codes: B60C9, B60C5