Abstract:
A method and apparatus  100  for forming an annular elastomeric tire component has the steps of extruding at least one elastomeric material annularly onto a support surface  60  and shaping the at least one strip  2  of elastomeric material to a predetermined profile by forming the at least one strip  2  of material between a shaping die  84  and the support surface  60  thereby smoothing and spreading the strip to the desired profile. The method may include applying additional strips  2  to form multilayered components. The support surface  60  may be separate from a tire building station  200  or may be integral to a tire building station  200.  The formed strips may include any one or more tire components such as a sidewall  20,  a chafer  30,  a bead apex  10,  ply stock coatings  40,  an innerliner  50,  or a tread  22.

Description:
TECHNICAL FIELD  
       [0001]     This invention relates to an apparatus for forming elastomeric tire components and a tire.  
       Background of the Invention  
       [0002]     It is well known in the prior art to manufacture tire components from elastomeric sheets of rubber which are then cut to length and lapped or butt spliced onto a cylindrically shaped building drum. The tire building drum is then expanded radially in the center and the ends are drawn in axially to shape the tire into a torus. Belts of cord-reinforced layers and a strip of tread rubber are applied over the crown of the green carcass to form a “green” or unvulcanized tire assembly. The finished tire assembly is then placed into a tire mold and cured in a process called vulcanization to make a tire.  
         [0003]     Since the tire components are assembled flat onto a cylindrical tire building drum and then expanded into a toroidal shape, each component has to be placed in tension or compression prior to being molded. This stretching of the various parts causes slippage between the various rubber parts as the components heat up during vulcanization. Attempts to minimize the slippage of the various parts have been attempted. Another disadvantage is that the tire has components which are spliced, and which contribute to tire nonuniformity.  
         [0004]     Tire manufacturers have been increasingly focusing their efforts on eliminating tire nonuniformities. More recently, tire manufacturers are making tire components from a continuous strip of unvulcanized rubber. A thin, narrow strip of unvulcanized rubber is circumferentially wound multiple times onto a rotating drum or toroid shaped core, wherein the strips are successively layered or stacked in order to form the desired shape of the tire component. See for example, U.S. Pat. Nos. 6,372,070 and 4,963,207. The strip of rubber is typically extruded directly onto a tire building drum or toroidal-shaped core using an extruding device. Alternatively the strips may be formed from calendering and then conveyed to the tire drum or core.  
         [0005]     This strip lamination method of forming tire components has the advantage of eliminating splices because the annular tire component is typically formed of one continuous strip. Strip lamination has the further advantage of allowing flexibility in manufacturing, since the tire component profile may be changed from tire to tire. However, there are several disadvantages to strip lamination. First, trapped air or air pockets may be formed in between the strips, creating gaps in the finished tire component. A second disadvantage to the strip lamination is that the contour of the tire component is an approximation due to the stacking of the strips which have a fixed geometrical shape. Further as a result of the stacking, the outer surfaces of the tire component are not smooth. The component contour typically has staggered top and bottom surfaces which can cause surface defects commonly referred to as “lights” or discolorations. A third disadvantage is that the strips need to be stitched to the drum or core using a pressure roller or stitcher, and the rubber tends to stick to the roller. A further disadvantage is that since the component is formed from multiple strips, it is only an approximation of the desired shape.  
       DEFINITIONS  
       [0006]     “Aspect ratio” of the tire means the ratio of its section height (SH) to its section width (SW);  
         [0007]     “Axial” and “axially” means lines or directions that are parallel to the axis of rotation of the tire;  
         [0008]     “Bead” means that part of the tire comprising an annular tensile member with or without other reinforcement elements such as flippers, chippers, apexes, toe guards and chafers, to fit the design rim;  
         [0009]     “Belt reinforcing structure” means at least two layers of plies of parallel cords, woven or unwoven, underlying the tread, unanchored to the bead, and having both left and right cord angles in the range from 17 degrees to 27 degrees with respect to the equatorial plane of the tire;  
         [0010]     “Carcass” means the tire structure apart from the belt structure, tread, under tread, and sidewall rubber over the plies, but including the beads;  
         [0011]     “Circumferential” means lines or directions extending along the perimeter of the surface of the annular tread perpendicular to the axial direction;  
         [0012]     “Chafers” refers to narrow strips of material placed around the outside of the bead to protect cord plies from the rim, distribute flexing above the rim, and to seal the tire;  
         [0013]     “Chippers” means a reinforcement structure located in the bead portion of the tire;  
         [0014]     “Cord” means one of the reinforcement strands of which the plies in the tire are comprised;  
         [0015]     “Design rim” means a rim having a specified configuration and width. For the purposes of this specification, the design rim and design rim width are as specified by the industry standards in effect in the location in which the tire is made. For example, in the United States, the design rims are as specified by the Tire and Rim Association. In Europe, the rims are as specified in the European Tyre and Rim Technical Organization—Standards Manual and the term design rim means the same as the standard measurement rims. In Japan, the standard organization is The Japan Automobile Tire Manufacturer&#39;s Association.  
         [0016]     “Equatorial plane” (EP) means the plane perpendicular to the tire&#39;s axis of rotation and passing through the center of its tread;  
         [0017]     “Footprint” means the contact patch or area of contact of the tire tread with a flat surface at zero speed and under normal load and pressure;  
         [0018]     “Innerliner” means the layer or layers of elastomer or other material that form the inside surface of a tubeless tire and that contain the inflating fluid within the tire;  
         [0019]     “Net-to-gross ratio” means the ratio of the tire tread rubber that makes contact with the road surface while in the footprint, divided by the area of the tread in the footprint, including non-contacting portions such as grooves;  
         [0020]     “Normal rim diameter” means the average diameter of the rim flange at the location where the bead portion of the tire seats;  
         [0021]     “Normal inflation pressure” refers to the specific design inflation pressure and load assigned by the appropriate standards organization for the service condition for the tire;  
         [0022]     “Normal load” refers to the specific design inflation pressure and load assigned by the appropriate standards organization for the service condition for the tire;  
         [0023]     “Ply” means a continuous layer of rubber-coated parallel cords;  
         [0024]     “Radial” and “radially” means directions radially toward or away from the axis of rotation of the tire;  
         [0025]     “Radial-ply tire” means belted or circumferentially-restricted pneumatic tire in which the ply cords which extend from the bead to bead are laid at cord angles between 65 degrees and 90 degrees with respect to the equatorial plane of the tire;  
         [0026]     “Section height” (SH) means the radial distance from the nominal rim diameter to the outer diameter of the tire at its equatorial plane; and,  
         [0027]     “Section width” (SW) means the maximum linear distance parallel to the axis of the tire and between the exterior of its sidewalls when and after it has been inflated at normal pressure for 24 hours, but unloaded, excluding elevations of the sidewalls due to labeling, decoration or protective bands. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0028]     The invention will be described by way of example and with reference to the accompanying drawings in which:  
         [0029]      FIG. 1  is a side perspective view of a rubber applicator apparatus of the present invention.  
         [0030]      FIG. 2  is a rear perspective view of the rubber applicator apparatus of  FIG. 1 ;  
         [0031]      FIG. 3  is a side view of a portion of the apparatus of  FIG. 1 , shown together with a tire building drum, in phantom.  
         [0032]      FIG. 4  is a front view of the rubber applicator apparatus of  FIG. 1 ;  
         [0033]      FIG. 5  is a cross sectional view of the rubber applicator apparatus taken in the direction  5 - 5  of  FIG. 4 ;  
         [0034]      FIG. 6  is a perspective view of a nozzle;  
         [0035]      FIG. 7  is a cross sectional view of the nozzle of  FIG. 6  in the direction  7 - 7 .  
         [0036]      FIG. 8  is a side view of a tongue assembly.  
         [0037]      FIG. 9  is a front view of the tongue assembly.  
         [0038]      FIG. 10  is a side view of the tongue assembly.  
         [0039]      FIG. 11  is a rear view of the tongue assembly.  
         [0040]      FIG. 12  is a top view of the tongue assembly.  
         [0041]      FIG. 13  is a side view of the rubber applicator apparatus and tongue assembly shown applying rubber to a tire building drum.  
         [0042]      FIGS. 14-16  illustrate perspective views of alternate nozzle assemblies. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0043]     A first embodiment of a rubber applicator apparatus  100  is shown in  FIGS. 1-13 . The applicator apparatus  100  provides a novel method and apparatus to form elastomeric tire components quickly and efficiently. The apparatus  100  permits the tire components to be quickly and efficiently formed from a single continuous wound strip or multiple strips of unvulcanized rubber. A continuous strip or strips of unvulcanized rubber may be applied directly onto a tire building surface such as a tire building drum A or a toroidal shaped core (not shown).  
         [0044]     As shown in  FIG. 1 , the applicator apparatus  100  includes a support frame  110  (parts of which have been removed for clarity), and a rubber applicator subassembly  200 . The support frame may further include support rails for translating the entire applicator apparatus in the X,Y and Z direction (not shown).  
         [0045]     The applicator apparatus  100  has a mounting flange  102  for connecting to a rubber pumping means  103  such as an extruder, gear pump, gear pump-extruder, or rubber injector (not shown). An extruder suitable for use with the invention is made by VMI AZ Formen und Maschienenbau of Munich, Germany. The rubber or elastomer output from the rubber pumping means is fed into a transition member  120 . As best shown in  FIG. 5 , transition member  120  has an interior channel  126  having an inlet end  122  and an outlet end  124 . The inlet end  122  preferably has a larger area than the outlet end  124 , resulting in a decreasing area or a funnel-shaped channel  126 . Channel  126  is also angled downwardly (angle θ), wherein θ is in the range of about 120 to about 165 degrees with respect to the Y axis, more typically about 135-150 degrees. The outlet end  124  of the transition member is connected to a rotatably mounted applicator head  130  which rotates about the Z axis. The applicator head can rotate in the range of about, 360 degrees, or more typically about ±150 degrees from the center position.  
         [0046]     The rotatable applicator head  130  further comprises an internal channel  132  which is fluid communication with the funnel shaped channel  126 . The channel  132  has a first portion  133  which is substantially aligned with the axis of rotation of the applicator head  130 , ie, the Z axis. The rubber or elastomer flow from the extruder to the inlet end  122  of the transition member is primarily oriented in the Y direction. Thus, the rubber or elastomer material flowing within the interior channels  126 , 132  changes from flowing predominantly along the Y axis, transitioning to flow substantially in a second direction parallel to the axis of rotation, for example along the Z axis prior to entering the rotatable applicator inlet  134 . Because the rubber material changes direction prior to entering the rotatable applicator head, the flow remains unaffected by the rotation of the applicator head. Since rubber or elastomers have memory, changing direction of the rubber material prior to rotation prevents the material from curling or otherwise having an undesirable non-uniform flow.  
         [0047]     Applicator channel  132  further comprises a second portion  136  having a decreasing area towards the applicator nozzle. The applicator channel  132  is also angled, forming an angle a in the range of about 120-150 degrees with respect to the Y axis, more typically about 135 degrees. The use of two angled channels  126 ,  136  instead of one steeply angled channel (about 90 degrees) results in less flow resistance, resulting in a more efficient system. Still further, the use of decreasing area channels further contributes to the efficiency of the system, requiring less energy to push the rubber flow out of the system.  
         [0048]     The outlet end of the applicator channel is in fluid communication with the inlet of a nozzle  150 . The nozzle  150 , as best shown in  FIGS. 6-7 , has an outer generally cylindrical profile with one or more angled faces  152 ,  154 ,  156 ,  158 . However, other nozzle configurations may also be used with the invention, as described in more detail, below. The interior channel  160  has a decreasing area towards the outlet orifice  162  of the nozzle. The nozzle channel  160  preferably has a length/diameter ratio in the range of 2-15, preferably about 5-7, and even more preferably about 6-7. The nozzle channel may optionally include a flow restrictor  165  in the form of an angled edge transverse to the direction of flow. The flow restrictor is preferably located in the center of the interior of the nozzle and functions to decrease the velocity of the flow of rubber located in the center of the nozzle increasing the velocity of the rubber at the outermost portions of the nozzle. This feature helps reduce the swell of the rubber. The interior channel  160  after the flow restrictor reduces to a short tube  168 . The outlet orifice  162  of the nozzle is shown with a trapezoidal shape, however other configurations may be used such as, but not limited to, square, rectangular, triangular, etc. The width of the rubber strip output from the nozzle orifice is typically about 15 mm in width, but may vary in the range of about 5 mm to about 30 mm. The nozzle  150  may be optionally heated to a temperature in the range of about 0 to about 230 degrees F., preferably in the range of about 0 to about 200 degrees F., using external or internal heaters (not shown).  
         [0049]     The nozzle may also have other external configurations, such as shown for example in  FIGS. 14-16 .  FIG. 14  illustrates a generally cylindrical nozzle  170  having a beveled edge  172  and a trapezoidal shaped orifice  174 .  FIGS. 15 and 16  illustrate nozzles  176 ,  180  which are similar in shape to the nozzle of  FIG. 14 , except that the side ends  178  have been radiused.  
         [0050]     As shown in  FIG. 13 , the nozzle  150  is oriented with respect to the tire building drum A, core (not shown) or other application surface typically at an angle β in the range of about 0 to about 90 degrees, more typically in the range of about 35-90 degrees. It is preferred that the rubber output from the nozzle be oriented about 90 degrees relative to the application surface, although β may range from about 35-90 degrees.  
         [0051]      1  Adjacent the nozzle is an optional tongue assembly  300 . The tongue  300  is rotatably mounted to a frame  310  having forked ends  312  which are rotatably mounted to the applicator apparatus  100 . Also mounted to the tongue support frame  310  are dual hydraulic or pneumatic cylinders  320  which press the tongue into engagement with the applicator surface as well as providing a shock absorbing or damping function. The tongue could also be spring mounted onto the support frame. The cylinders allow the tongue to “float” over the drum, which is important due to the drum runout or uneven surface. The tongue engagement pressure may be variable and may range from about 0 to about 100 psi. The tongue  300  as shown in  FIGS. 9-12 , has a generally outer convex surface  303  with rounded edges and a beveled lip  330  which engages the applicator surface. The tongue  300  may also comprise additional shapes such as flat surface, convex or radiused outer surface or a concave surface.  
         [0052]     The tongue assembly preferably has internal heaters for heating the outer surface in the range of about 200 to about 400 degrees F., and more preferably in the range of about 350 to about 400 degrees F. Thus the tongue functions as a hot knife, smoothing and smearing the freshly deposited rubber, melting and blending the adjacent strips of rubber together, into a homogeneous mass. The higher tongue temperature does not impact the curing of rubber due to the short residence time of the tongue on the rubber. The tongue assembly also performs a stitcher function due to the pressure of the tongue against the drum, smoothing out the air pockets. The outer surface of the tongue also helps shape the formed component.  
         [0053]     The following steps describe the formation of a tire component such as a sidewall, chafer, liner, or other elastomeric article. Rubber or elastomer is fed to a pumping means, such as an injector, gear pump, extruder or combination thereof. The extrudate then enters the applicator head  100 . In the applicator head, the elastomeric material is fed through a first stationary channel, a transition channel and then a second channel. The first channel is stationary, while the transition channel and the second channel are contained within the rotatable head. Each channel has a decreasing area from the inlet end to the outlet end and is angled downwardly, taking advantage of gravity. In between the first and second channels is a short vertical transition channel. In the short transition channel the extrudate flows vertically. The advantage to this configuration is that the rotatable head can pivot without affecting the fluid dynamics of the rubber. The flow exits the second channel and enters a nozzle. The nozzle has a decreasing area and a flow restrictor. The nozzle is oriented at an angle with respect to a tire building surface or core. The nozzle assembly is capable of translating in three directions in discrete index positions in order to accurately apply the rubber to the building surface. The support surface can be is a toroid shaped core or a cylindrical shaped tire building drum, or any other desired shape. The primary advantage of applying the strip to a toroidally shaped surface is the finished part is accurately positioned in a green uncured state at the proper orientation to be molded without requiring any change in orientation from the condition in which the strip was initially formed.  
         [0054]     The extrudate exits the nozzle in a strip form, having the desired shape of the exit orifice of the nozzle. If a drum or toroid is used as an applicator surface, as the drum or core rotates, a continuous annular strip may be formed. The nozzle can be indexed axially so to form the desired shape of the component. The nozzle can be controlled by a control system wherein the movement of the nozzle so that the multiple layers of strip dictates the shape of the desired tire component.  
         [0055]     An optional tongue which is preferably heated is located adjacent the nozzle. The tongue is rotatable mounted near the nozzle to a frame. The tongue assembly may also be connected to a damping device such as a pneumatic or hydraulic cylinder which dampens the movement of the tongue in response to the drum variation in diameter (drum runout). The tongue assembly is preferably heated to a temperature so that the tongue heats adjacent strips of rubber, while smoothing and compressing the strips in order to form a solid monolithic mass.  
         [0056]     The profile of each formed component can be varied in a fashion such that the cross-sectional thickness is very thin as in the tip of an apex or thick near the bead core. Also the entire profile can be thin as in a liner component. The nozzle and/or tongue assembly can articulate moving in numerous directions the numerous degrees of freedom enabling the nozzle/tongue assembly to form flat, convex or concave curvatures as the material is spread. In addition, the numerous degrees of freedom allow the components such as a sidewall to be built. What is important to note is some or all of these tire components can be formed using this technique of the present invention. The tire manufacturer simply can choose which components can be most efficiently produced using this technique.  
         [0057]     Variations in the present invention are possible in light of the description of it provided herein. While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. It is, therefore, to be understood that changes can be made in the particular embodiments described which will be within the full intended scope of the invention as defined by the following appended claims.