Patent Publication Number: US-8114330-B2

Title: Method for vacuum forming an elastomeric tire

Description:
This application is a Divisional application of application Ser. No. 10/936,635, for “AN APPARATUS FOR VACUUM FORMING AN ELASTOMERIC TIRE”, filed Sep. 4, 2004, now U.S. Pat. No. 7,399,172. 
    
    
     BACKGROUND OF INVENTION 
     1. Field of the Invention 
     This invention pertains to methods and apparatus for vacuum forming an elastomeric transport tire containing a core of belts, plies and beads. 
     2. Prior Art 
     The present invention is in a new and unique vacuum forming apparatus for use in an automated method for forming a transport tire from an elastomeric material that includes a core of optimally positioned belts, plies and beads, to provide a balanced transport tire. 
     Heretofore it was recognized that venting air from a tire tread mold cavity early in a casting process could eliminate the necessity for venting the cavity through spaced holes in the mold that materials from the tread flowed into during casting and formed projections or “tits”. Such extensions or ‘tits’ projected from the tread surface and were either pulled off when the tire was removed from the mold, had to be cut off or wore off during tire use. To prevent this undesirable cosmetic anomaly it was recognized that air could be vented from the mold cavity just before tread casting, eliminating a necessity for providing flow passages or vents from the tire tread mold while still obtaining a smooth, un-pocketed or un-blemished, finished tread surface. Examples of such an introduction of a vacuum into a tire mold just prior to forming a tire tread are shown in U.S. Pat. Nos. 4,573,894 and 5,152,951. 
     U.S. Pat. No. 4,573,394 sets out a tire mold having a cavity that is for receiving and finally shaping the tire. The patent is defined by a surface that is for contacting the exterior of the tire during tire curing. The cavity is fluid connected to a single vacuum source for evacuating air from within the cavity during an early portion of a tire curing cycle to prevent air and any other fluid from becoming trapped between the tire and the surface that defines the cavity that will become the tire tread. Visual effects in the form of voids in the tire exterior are, thus eliminated. 
     Like the &#39;894 patent, U.S. Pat. No. 5,152,951 also provides for the elimination of fluid from the mold cavity during an early portion of a tire curing cycle. The patent provides for fluid evacuation through a space between the surfaces of the mold parts that defines the mold parting line region. Both patents provide a single vacuum source and its connection to the mold cavity for forming the tire side wall and tread surfaces. Whereas, the present invention provides for both an evacuation of air from the elastomeric mixture prior to its introduction into the mold cavity, and for pulling the air free mixture through the mold. With that flow filling the area between inner and outer mold walls, traveling through the core of plies, belts and beads, to form a finished transport tire that is free of voids or pockets. 
     A core of plies, belts and beads for use in the vacuum forming apparatus of the invention is set out in a U.S. patent application for a “Tire Core Package for Use in Manufacturing a Tire With Belts, Plies and Beads and Process of Tire Manufacture” Ser. No. 10/143,678, filed May 13, 2002, of two of the inventor, and is presently pending. This patent application sets out a process, utilizing a sandwich of pre-cured elastomer layers between layers of plies and belts formed over a mandrel for fitting into a mold, for forming a tire utilizing a spin casting method. Also, one of the inventors of the present application is the sole inventor of a U.S. patent application for an “Elastomeric Tire With Arch Shaped Shoulders” filed May 28, 2004, assigned Ser. No. 10/856,652. 
     The present invention is a new approach to forming a transport tire from an elastomeric material from earlier patent applications for spin casting apparatus and methods for use in such spin casting apparatus for forming a transport tire that are shown and discussed in a recently filed U.S. patent applications of two of the inventors, entitled, “Method and Apparatus for Forming a Core of Plies, Belts and Beads and For Positioning the Core in a Mold For Forming an Elastomeric Tire and the Formed Elastomeric Tire”, filed Jun. 4, 2004, Assigned Ser. No. 10/860,997, and an “Improved Method and Apparatus for Forming a Core of Plies, Belts and Beads and for Positioning the Core in a Mold for Forming an Elastomeric Tire”, filed Aug. 2, 2004, assigned Ser. No. 10/809/807. All of which earlier patents are directed to spin casting methods and apparatus and do not involve a vacuum forming apparatus and method as does the present invention. 
     SUMMARY OF THE INVENTION 
     It is a principal object of the present invention to provide a vacuum forming apparatus and method for its use for forming a transport tire containing a core of plies, belts and beads encapsulated therein that are optimally positioned to provide essentially a perfectly balanced tire. 
     Another object of the present invention is to provide a vacuum apparatus for forming an elastomeric tire with a core of plies, belts and beads is encapsulated therein in a single operation, where air is removed from the elastomeric material mixture prior to its passage into the mold and the elastomeric material is pulled, under vacuum, through the mold, filling essentially all the voids in, between and through the core layers to form a homogenous tire where the core of plies, belts and beads is optimally positioned therein. 
     Another object of the present invention is to provide a vacuum casting apparatus that includes a canister that is initially placed under a deep vacuum as it receives a volume of mixed elastomer constituents, with the vacuum pulling air from the mixture, and whereafter the canister is opened to atmosphere and the column of the air-free mixture is allowed to pass through a canister exhaust valve and travel into a mold cavity that is at a low-level vacuum, wherein a core of plies, belts and beads is maintained in a cavity between inner and outer mold surfaces, with the low level vacuum pulling the air-free mixture across the core, filling the mold cavity, and is allowed to cure into a homogeneous finished tire. 
     Another object of the present invention is to provide a mold with a cavity as a component of a vacuum forming apparatus with a reservoir that connects to a vacuum source that is opened at a top end to receive a mix of elastomeric material constituents and is subjected to a deep vacuum that draws the air from the mixture in preparation for its passage through a vent valve into the mold cavity that is under a low-level vacuum. 
     Another object of the present invention is to provide for connection of the reservoir canister with the mold annular area that contains a mandrel whereon a tire core of plies, belts and beads with separators has been laid up and crowned by a wrap of tire cord, with the mold cavity is under a low-level vacuum, and the reservoir canister is under a deep vacuum such that air trapped in an elastomeric mix pour therein is removed and, when the canister valve is opened, the air-free elastomeric material mix is pulled into the mold cavity, traveling through and across, to fully encapsulate, the tire core, forming a homogenous tire. 
     Another object of the present invention is to provide a vacuum forming apparatus where a core of tire belts, plies and beads will be encapsulated at an optimum position in a finished tire to provide a near perfectly balanced finished tire. 
     Still another object of the present invention is to provide a vacuum forming apparatus for manufacturing an elastomeric tire where, in the formation process, essentially all air is removed from the elastomeric material mixture before its passage into a mold wherethrough the material is pulled, under a low level vacuum, to completely permeate through and around a core of plies, belts and beads and spacers maintained in the mold cavity, forming, in a single molding operation, a tire that is ready for removal from the mold after cooling. 
     Still another object of the present invention is to provide, a mandrel whereon a core of plies, belts and beads with spacer is laid up, for fitting in the vacuum forming apparatus that includes a canister to receive a mixture of elastomeric material constituents for connection to a vacuum source to provide a deep vacuum in the canister that removes trapped air from elastomeric mixture, with the air-free mixture then passed through a valve into the mold cavity that is connected to a low level vacuum that pulls the mixture through the tire, forming a transport tire. 
     Still another object of the present invention is to provide for seals for maintaining canister and mold integrity when they are subjected, respectively, to a deep vacuum and a low level vacuum. 
     Still another object of the present invention is to provide a vacuum forming apparatus for casting a transport tire containing a core of plies, belts and beads in a single operation, producing a homogenous tire that is essentially perfectly balanced. 
     The present invention is in a vacuum forming apparatus that receives a mold arranged therewith that includes of an inner mold that maintains a mandrel whereon is built-up a core of plies, belts and beads with spacers or separators therebetween. Which inner mold mandrel is for fitting into an outer mold whose annular surface has the shape of the outer surface of a transport tire, and which outer mold is easily opened to allow for removal of a tire formed therein. A mold canister is provided that is to receive a mix of elastomeric constituents and connects to a deep vacuum source for removing air from which mix. With, after air removal, the mix is passed through a needle valve into an annular area between the inner mold mandrel and the outer mold that is under a low level vacuum that pulls the mix through the mold. The elastomeric material mix is passed through and around to encapsulate the tire core. Seals are provided within the apparatus, between a cover and outer mold top, around the mold body, and at the canister, to contain both the deep and low level vacuums that are preferably generated by separate vacuum sources. 
     Upon receipt of a set volume of the elastomeric material mix the canister is sealed and is subjected to a deep vacuum. The vacuum is pulled through a port in the cannister, and is operated until the mix in the canister is essentially free of all the air that had been trapped therein during the mixing process. Thereafter, with the mold maintained under a low level vacuum that is pulled through a port in the cover, the canister is opened through a needle valve and is open to outside air, and vents into the mold annular or hub area, pulling the air free elastomeric mix therein by the low level vacuum. The mix passes through and around the core, thoroughly penetrating and bonding to all the core constituent threads and cords, with any air in the mold traveling ahead of the mix flow to the cover port wherethrough the low level vacuum is being pulled. In practice, the needle valve is required to be closed before the canister is empty and comes under ambient air conditions as are present in the canister. After cooling, the mold is broken open and a completed transport tire containing perfectly positioned core of plies, belts and beads, is removed therefrom. 
     In a practice of the method, utilizing the apparatus of the invention, for forming, in a single operation, a transport tire includes: passing a volume of mixed elastomeric material constituents into a mold canister that is preferably, but may not necessarily be, centered in the mold that includes inner and outer mold components, and is easily opened after casting for removal of a finished transport tire. With the inner mold to function as, or includes a mandrel portion, whereon a core of plie, belts and beads, with spacer or separators therebetween, has been laid-up thereon, and the annular inner surface of the outer mold has a tire tread pattern embossed therearound. 
    
    
     
       DESCRIPTION OF THE DRAWINGS 
       The invention may take physical form in certain parts and arrangement of parts, used to form the apparatus of and practice the steps of the invention that are herein shown as a preferred embodiment and will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof: 
         FIG. 1  shows an exploded perspective view taken from above a bottom hub plate whereto a cylindrical hub manifold is being fitted with studs turned into the bottom hub plate, forming an inner mold for use with the apparatus of the invention, practicing the process of the invention; 
         FIG. 2A  shows the inner mold components of  FIG. 1  receiving a pair of hard foam core segments fitted over the studs; 
         FIG. 2B  shows all but a pair of the hard foam core segments assembled to the bottom hub as a mandrel for receiving a core of plies, belts and beads for a transport tire core laid-up thereon; 
         FIG. 3A  shows the completion of the hard foam core segments assembly and with a top hub plate fitted onto the hard foam core segments; 
         FIG. 3B  shows the top hub plate being bolted onto the top of the cylindrical hub manifold; 
         FIG. 4A  shows the hard core assembly of  FIG. 3B  as having been mounted onto an axle that is fitted to a pivoting arm, with the hard core assembly shown rotated ninety degrees, showing an expander cone aligned with the side of the hard core assembly, and showing a sleeve woven from ply cords aligned to fit over the expander cone smaller end; 
         FIG. 4B  shows a top plan sectional view taken along the line  4 B- 4 B of  FIG. 4A  looking down on the hard foam core assembly with the expander cone large diameter end slid along the expander cone to the center of the hard core assembly, showing the plies sleeve aligned for fitting over the expander cone small diameter end; 
         FIG. 4C  is a view like that of  FIG. 4B  except that the plies sleeve end has been drawn over and beyond the hard core assembly; 
         FIG. 5A  is a view like that of  FIG. 4C  only showing a pair of bladder and hard plate assemblies for bead centering and plies cords positioning aligned with the ends of the plies sleeve; 
         FIG. 5B  is a view like that of  FIG. 5A  only showing the left bladder and hard plate assembly, that is a bead centering plate, as having passed into the plies cords sleeve end to where the hard plate contacts the side of the hard core assembly and showing a bead maintained by the hard plate edge against the hard core assembly left side; 
         FIG. 5C  is a view like that of  FIG. 5B  that additionally shows the right bladder and hard plate fitted into the plies cords sleeve end and showing a bead maintained by the hard plate edge against the hard core assembly right side; 
         FIG. 5D  is a view like that of  FIG. 5C  only showing a press plate engaging the expanded left bladder, and with the bladder inflated; 
         FIG. 5E  is a view like that of  FIG. 5D  only showing the press plate as having been urged against the expanded bladder as air is removed, at a controlled rate, from the bladder, causing the bladder to fold the plies cords over the bead and up the left side of the hard core assembly; 
         FIG. 5F  is a view like that of  FIG. 5E  only showing the press plate as having been moved to its limit of travel against the bladder and has been deflated to extend the bladder around the hard core assembly shoulders, pushing the plies cords ahead of the bladder surface; 
         FIG. 6A  shows a top plan view like that of  FIG. 4B  except that the expander cone is shown fitted over the hard core assembly whereon the plies and beads have been assembled, and a separator, that is a layer of cotton batting, as having been applied therearound, and showing a first belt sleeve fitted onto the expander cone and a second belt sleeve, that is shown as a weave formed from crossing sections of belt cord, aligned with the expander cone smaller end and showing, with arrows A, the belt sleeve traveling up the expander core; 
         FIG. 6B  shows the hard core assembly with the plies ends extending up the hard core assembly sides, with spacers arranged between the plies and belt and with a final layer of tire cord wound around the crown; 
         FIG. 7A  shows a view like that of  FIG. 6B  only showing a layer of cotton batting wound around the core circumference; 
         FIG. 7B  shows a view like that of  FIG. 7A  and additionally illustrates, with a spool, that a continuous cord is being rolled off the spool, and is wound around the crown that has been covered by a separator layer of cotton batting; 
         FIG. 7C  shows a view like that of  FIG. 7B  only with the wound tire cord shown as covering the crown; 
         FIG. 8A  shows the hard core assembly, with the tire core wound thereon, removed from the axle and positioned onto a mold base; 
         FIG. 8B  shows one of a number of tread segments that are fitted together to form the exterior or outer mold; 
         FIG. 8C  shows the tread segments of  FIG. 8B  assembled into the mold outer wall; 
         FIG. 8D  shows a top plate installed onto the assembly of  FIG. 8C  showing a center opening wherethrough a center cylindrical canister of a vacuum forming apparatus of the invention is fitted; 
         FIG. 8E  shows a view like that of  FIG. 8D  only showing a dome shaped cover mounting a head end of center cylindrical canister fitted onto the outer mold cover with the center cylindrical canister fitted into, and extending upwardly from, a center opening, and showing first and second vacuum ports fitted, respectively, into the side of the center cylindrical canister and the top of the dome shaped cover; 
         FIG. 9A  shows a sectional view taken along the line  9 A- 9 A of  FIG. 8E  with the dome shaped cover lifted off of the outer mold top, with arrows B illustrating the dome cover as being lowered onto the outer mold top that contains the core of belts, plies and beads laid up on an inner mold mandrel portion, showing, with arrow C, movement of a pouring head into an opening through the top of a deep vacuum canister, and showing with arrow D movement of a needle valve into a bottom end throat of the deep vacuum cylindrical canister; 
         FIG. 9B  is a view like that of  FIG. 9A  only showing the dome shaped cover as having closed over the outer mold top, with a pour of an elastomeric material, arrow E, passed through the pouring head into the deep vacuum canister and showing, with arrow F, a high level vacuum being pulled through a canister port, with that pulled air, shown as arrows G, passing out of the elastomeric material pour, and shows a low level vacuum, shown as arrow H, being pulled through a cover port, pulling air, shown as arrows I, from within the mold cavity and area under the cover; 
         FIG. 9C  is a view like that of  FIG. 9B , only showing the pouring head closed, with the elastomeric material sans air contained in the deep vacuum canister and with the canister port shown as open, admitting ambient air, arrow K, into the canister, and showing the needle valve at the bottom of the canister as just opening, passing a flow of the elastomeric material therefrom, pushing air ahead of the flow of elastomeric material, shown as arrows I, that is pulled by the low level vacuum, arrow H; 
         FIG. 9D  is a view like that of  FIG. 9C  only showing most of the elastomeric material as having been evacuated from the deep vacuum canister, through the needle valve that has been closed, and showing the elastomeric material as having passed through and around core of plies, belts and beads and separator layers maintained on the inner mold mandrel, and with the elastomeric material shown as having passed up the canister side and just entering the area beneath the dome shaped cover, following the air flow, arrow I, out from the outer mold through cover port wherethrough is being pulled a low level vacuum, arrow H, completing the tire formation; 
         FIG. 10  shows a side elevation exploded sectional view of a section of a tire manufactured by the process and with the apparatus of the invention as has been removed from the outer mold of  FIG. 9D ; 
         FIG. 11  shows an assembled view of the tire of  FIG. 10 ; and 
         FIG. 12  shows a block flow schematic of the steps practiced to form a tire of  FIGS. 10 and 11  utilizing the vacuum forming apparatus of the invention. 
     
    
    
     DETAILED DESCRIPTION 
     The invention is in a process and apparatus for forming a transport tire with vacuum forming apparatus  90  of the invention, wherein a core of belts, plies and beads is optimumally positioned, forming a transport tire that is like the tire  130  of  FIG. 11 . The vacuum forming apparatus  90 , like earlier spin casting processes and apparatus such as those of the inventors identified hereinabove in the Prior Art section of the present application, provides for forming, in a single operation, an essentially perfectly balanced transport tire containing plies, belts and beads, with the tire then pulled from the mold. 
     Like earlier spin casting apparatus and methods of manufacture for practice thereon, as set out in the Prior Art section of the present application, the vacuum forming apparatus of the invention, as herein shown in  FIGS. 8E and 9A  through  9 D, employs a mold containing a mandrel in its cavity portion whereon is laid up a core of plies, belts and beads with separators fitted therebetween. One such arrangement of a mandrel as the outer surface of an inner mold that is used to lay up thereon a core of plies, belts and beads is set out in  FIGS. 1 ,  2 A,  2 B,  3 A,  3 B,  4 A through  4 C,  5 A through  5 F,  6 A,  6 B, and  7 A through  7 C. With a final core formed on the inner mold mandrel shown in  FIG. 8A , and with an outer mold for containing the inner mold shown assembled in  FIGS. 8B through 8D . It should, however, be understood that the inner mold with its mandrel portion and outer mold arrangements can be varied, and other mold arrangements can be substituted therefore, within the scope of this disclosure, to operate with the vacuum forming apparatus  90  of the invention, as set out in  FIGS. 8E , and  9 A through  9 D to manufacture a transport tire that is like the tire  130 , as shown in  FIG. 11 . 
     For forming the inner mold  30  of  FIG. 3B , that includes a mandrel formed by assembling tread segments  45   a  and  45   b  into a cylinder, as shown in  FIGS. 2A and 2B , to have the shape of a transport tire inner surface, an inner mold hub base  31   a , as shown in  FIG. 1 , is used. The inner mold base  31   a  is shown as having a center dish  32  with a center opening  33  that includes spaced elliptical ports  34 , and is stepped upwardly into a continuous shelf  35  that posts  36  are mounted to, to extend at right angles therefrom. Which posts  36  are located at spaced intervals to one another, and each post includes a threaded nut  37  that is secured onto each post end  36   a . Outwardly from the posts  36 , the hub base  31   a  is stepped upwardly into a lip  38  and, outwardly from the lip  38 , it is stepped downwardly into a flat portion  39  that extends to the plate edge. Shown in  FIG. 1 , a cylindrical hub  40  is fitted onto the mold hub base  31   a  Which cylindrical hub has a center opening  42  therethrough, has its lower end aligned to fit onto the center dish area  32 , and is positioned thereon to align spaced elliptical ports  41  with the spaced elliptical ports  34  of the hub base. The cylindrical hub  40  is maintained in position by fitting a rod  43  through a side longitudinal hole  44  and turning a rod threaded end  43   a  into a threaded hole  44   a  that is formed into a side of the hub base  31   a.    
       FIG. 2A  shows the hub  40  fitted onto the inner mold hub base  3  la and is maintained thereon by the rod  43  threaded end  43   a  turned into the hub base threaded hole  44   a , as shown in  FIG. 1 .  FIG. 2A  shows mounting holes of the hard foam core top and bottom sections  45  and  45   b , respectively, that form the mandrel, with each hard form core section receiving one of the posts  36  fitted therethrough. With, in  FIG. 2B , all but one pair of hard foam core top and bottom sections  45   a  and  45   b  have been fitted onto posts  36 , and nuts  37  are shown as having been turned onto the post threaded ends  36   a.    
       FIG. 3A  shows the top of the hub  40  with the hard foam core top and bottom sections  45   a  and  45   b  assembled thereon, forming the mandrel, that is aligned with a hub top  31   b  with, it should be understood, the hub base and top,  31   a  and  31   b , respectively, being a mirror image of one another.  FIG. 3B  shows the hub top  31   b  fitted onto the top of hub  40 , with spaced elliptical ports  41  formed through the hub top  31   b  that includes elliptical ports  47  that align with the elliptical ports  41  in hub  40  and the elliptical ports  34  in the hub base  31   a , proving flow paths through the assembly, and showing bolts  47  each aligned for turning through the hub top  31   b  and into a nut  37 . With each nut  37  shown as having been turned onto a threaded end  36   a  of each post  36 , completing the assembly of the inner mold  30 , where the assembled hard foam core sections function as a mandrel for building up tire core  75  of  FIG. 8A  thereon. 
     To prepare for forming which tire core  75 , as shown in  FIG. 4A , the inner mold  30  has had an axle  48  mounted through the aligned center openings  33  in the hub base and top  31   a  and  31   b , as part of a build stand that allows the inner mold  30  to be pivoted from a horizontal attitude through ninety degrees, and with the axle  48  extending at a right angle outwardly from a pivot post  49 . Which pivot post  49  preferably includes a pivoting joint  50  that allows the inner mold  30  to be pivoted to a horizontal attitude, and with the base  51  thereof arranged to allow for three hundred sixty degrees of rotation. 
     To begin to form the core of plies, belts and beads  75 , as shown in  FIG. 10 , that is for positioning in the vacuum forming apparatus of the invention, as shown in  FIG. 4A , a layer of spacing material  52  is wrapped around the inner mold  30  crown, that is preferably at least a two ply or layers of cotton batting. An expander cone  53 , that is shown as a truncated cone having a greater diameter forward end  53   a  and a lesser diameter rear end  53   b , is fitted onto, to slide along axle  48 . The expander cone  53  is to receive a sleeve  54  that is sleeve woven from plies cord that, for a practice of the invention, is preferably rayon or cotton cord that, in practice, has been found to accept a flow of the elastomeric material into the cord surface, providing a weld of the cord and elastomer that is resistive to separation. Which sleeve, as needed, can include strands of an elastic material woven therein to allow for expansion as the sleeve is fitted over the expander cone lesser diameter rear end  53   b  and drawn therealong. 
       FIG. 4B  shows the expander cone  53  as having had its forward end  53   a  moved over the edge of the layer of spacing material  52  to approximately the center of the inner mold  30  mandrel crown. Which expander cone, to allow such movement, includes spaced parallel forward and rear inner walls  55   a  and  55   b , respectively, that each have a center hole  56   a  and  56   b  therethrough that align to receive the axle  48 . The axle  48  supports and guides the expander cone  53  as it is slid back and forth therealong. 
       FIG. 4C  shows the components of  FIG. 4B  except that the forward portion of the plies sleeve  54  has been pulled across the inner mold  30  mandrel, with the back section still supported by the expander cone  53 . 
       FIG. 5A  shows the view of  FIG. 4C , except that a pair of bladder and hard plate  60  have been aligned with the plies sleeve  54  ends. Each bladder and hard plate  60  includes a flexible bladder  62  and hard plate  61 , which hard plate is a hard metal or plastic and is for centering a bead to a side of the core in the core formation process. The hard plate  61  is mounted onto a side of a balloon type bladder  62  that is to be filled with air under pressure through a valve stem  63 . Beads  59  are shown as having been slid along the sleeve  54  into position to receive the hard plate ends  61  fitted there against and showing a separator layer  52  wrapped around the inner mold  30 . So arranged, the sleeve  54  is shown as having been passed thereover. 
       FIG. 5B  is a view like that of  FIG. 5A  only showing the left side bladder and hard plate  60  as having passed into the plies sleeve  54  end to where the hard plate  61  edge  61   a  is in engagement with the bead  59 , through the sleeve  54 . Which bladder and hard plate  60  passage is made possible by appropriately filling or emptying the bladder  62  to a desired air pressure through the valve stem  63  to have a diameter where it can be fitted through the sleeve  54 . 
       FIG. 5C  is a view like that of  FIG. 5B  only showing both of the bladder and hard plates  60  as having been passed into the plies sleeve ends, with the beads  59  held against the sides of the inner mold  30 , and the plies sleeve  54  beginning to be folded around the beads  59 . 
       FIG. 5D  is a view like that of  FIG. 5C  only showing the plies sleeve ends as having been cut to a lesser length to ends  54   a  and  54   b  and showing the bladder  62  of the left bladder and hard plate  60  as having been expanded with air, under pressure, passed through the stem  63 , as illustrated by an inwardly pointing arrow. With that expansion, the plies sleeve end  54   a  is elevated to align with the side of the inner mold  30 , and showing a pressure plate  64  in contact with, and pressing against, the expanded bladder  62 . Which pressure plate includes a flat piston end  65  whose forward face is in contact with the expanded bladder  62 , and a push rod end  66  that extends, at a right angle from, the piston end rear face. Of course, the plies sleeve  54  can be of lesser length to avoid having to cut off the sleeve ends and, also within the scope of this disclosure, the plies sleeve ends  54   a  and  54   b  can be left long and folded over the inner mold crown. 
       FIG. 5E  shows the pressure plate  64  as having advanced into the bladder  63 , as air is being withdrawn from the bladder, as illustrated by an outwardly pointing arrow, and shows the bladder as tending to fold around the shoulder of the inner mold  30 . Which bladder folding tends to urge the cords of the plies sleeve end  54   a  away from the bead  59 , with the cord ends folding onto the plies sides, and stretched across the inner mold  30 . Which operation can include coating the plies cords above the beads with an adhesive, such as a pre cure elastomer, before the plies cords ends are moved by the deflation of the bladder  62 . 
       FIG. 5F  is a view like that of  FIG. 5E  only showing the bladder  62  as having been further deflated as air is continued to be withdrawn through stem  63 . So arranged the bladder has flowed around the inner mold  30  shoulders with, in that flow, the bladder surface has tended to stretch the plies cords ends  53   a  away from bead  59  and urge the plies cords ends into close engagement with the plies cords above the bead. Which action tends to force any trapped air out from the bonding material and between the plies cords and plies cords ends. While the operation of the left bladder and hard plate  60  only has been shown, it should be apparent that the operation of the right side bladder and hard plate  60  is identical, and which bladders and hard plates  60  can operate simultaneously, producing, when the bladders and hard plates are removed, a core of plies and beads that is ready to receive a belt or belts applied around the inner mold crown, as set out below. 
     The above description of  FIGS. 4A through 4C  and  5 A through  5 F sets out a process for providing a core of plies and beads that are formed in layers on the mandrel portion of the inner mold  30 . With, in  FIGS. 5A through 5F , the plies cords are shown cut to fold to above the bead but do not extend beyond the inner mold shoulders. Though, it should be understood within the scope of this disclosure, that the plies ends can be folded across the mandrel crown, crossing one another, dependent upon the lengths of the cord plies ends. 
     Shown in  FIG. 6A  the core of plies and belts of  FIGS. 5A through 5F  has received a separator layer or layers  67  that are preferably sections of cotton batting installed around the inner mold  30  mandrel crown. Thereafter, a belt expander  68 , that is like and functions like, and in practice may be the same as the truncated cone plies expander  53 , so long as its greater diameter end will fit over the side of the inner mold whereon have been formed the plies with separator layers, extending to at or near to the center of the inner mold crown. So arranged, as shown in  FIG. 6A , a first belt  69  and, as required, a second belt  69   a  can be passed over the belt expander  68  lesser diameter end and slid therealong, as illustrated by arrows A. The first belt  69  is fitted across the inner mold  30  crown, followed by a separator layer  70 , as shown in  FIG. 6B , followed by the second belt  69   a . Whereafter, the belt expander  68  is removed and a top separator or spacer layer  71  is applied to the top surface of the second belt  69   a , as shown in  FIGS. 6B and 7A . A preferred spacing material is a four layer section of cotton batting that is approximately eight inches wide, and is wound circumferentially around the crown to hold the plies in place. The sides of which final separator spacer layer  71  are, in turn, pulled down around the inner mold  30  shoulders, engaging the plies  54 , as shown in  FIG. 7B . Finally, a tire cord  72 , that is shown in  FIG. 7B  being wound off of a spool illustrating a continuous cord, is applied by winding a strand of tire cord around the belt circumference, with the winding starting on one side of the crown and proceeding to the other crown side, as shown in  FIG. 7C , completing the assembly of the core of plies, belts and beads  75  of the invention as shown in  FIG. 10 . 
     For belt formation and application, as shown in  FIGS. 6A and 6B , the sleeves of belts  69  and  69   a  are preferably formed separately by weaving methods where the belt cords are woven together to cross and have a twenty four degree cord angle to the center of the belt circumference, and after the first belt  69  is fitted to the inner mold, a layer of a separator  70 , that is a gauze material, preferably cotton batting, having approximately four layers, is wrapped around the first belt  69  circumference. Whereafter, the second belt  69   a , as set out above, is installed over the separator  70 . Should additional belts be required, each belt is separated from the belts below and above by a separator, that is also preferably sections of cotton batting. A final separator layer  71  is applied over the top belt. A tire wrap  72  consisting of a winding of tire cord, that is preferably a Kevlar cord, is applied over the final separator layer  71 , as described above and as shown in  FIG. 7B , as being wound off of a spool  73  and around the crown, with the winding traveling from one side of the crown to the other. Such winding can be accomplished as by turning the inner mold and winding a Kevlar cord across the inner mold circumference, completing the core  75  formation on the inner mold  30  mandrel. 
     The core  75 , shown in  FIGS. 8A ,  8 C and  10 , is turned and is moved onto an outer mold base  85 , shown in  FIG. 8C , that receives tread segments  86  or a ring having a tread formed around the crown of its inner surface, not shown. The tread segments are individually numbered and are fitted together, in numerical order, around the outer mold base  85 , encircling the outer mold base and forming a cylinder, as shown in  FIG. 8C . Which tread segments  86 , for practicing the invention, include seals  86   a , shown in  FIGS. 9A through 9D , fitted between the adjacent tread segments  86  and between the tread segment  86  and the outer mold base  85  and outer mold top  88 , shown in  FIG. 8D , with a sectional view of which outer mold base  85  and outer mold top  88  shown in  FIGS. 9A through 9D . Which tread segment seals  86   a  are provided for blocking a flow under vacuum of the elastomeric material out of the cavity between the inner and outer molds during vacuum forming, as discussed hereinbelow. As shown in  FIG. 8D  the outer mold top  88  has been fitted across the cylinder of tread segments  86  completing the outer mold. Which outer mold top  88  that includes a vacuum forming apparatus top cover  89  that includes a center opening  89   a  and is for fitting over an apparatus top plate  91  that fits over a top bead alignment plate  92   a , with a space  91   a  and  94 , respectively, between the apparatus top plate  91  and the undersurface of the top bead alignment plate  92   a  as a vent opening. A seal  96  is fitted between an edge of a center hole  88   a  formed through the outer mold top  88 , and the cylindrical canister  95  surface  95   a , blocking passage of air therethrough. With the seals  86   a  provided between the tread segments  86  and the outer mold top  88  and outer mold base  85  apparatus bottom plate  87 , sealing off the mold annular cavity wherein the core  75  is positioned. 
     The outer mold base  85  apparatus bottom plate  87  supports a combination bead alignment and needle valve positioning plate  92   b , and has an outer grooved edge  93   b  that, like the top bead alignment plate outer grooved edge  93   a , supports the bead  59 , and further includes a center opening  96   a  wherethrough a neck mid-portion  101  of a needle valve  100  travels up and down in operation of the vacuum forming apparatus  90  of the invention. To compensate for a difference in diameter of the cylindrical canister  95  outer surface  95   a  from its top end  105  to a lower portion that necks in from  106  as a funnel area  107  to a nozzle end section  108 , a plug  10  is provided that is fitted through the opening  33  in a lower center dish  32 . Which plug  110  is shaped to fit and seal against the outer surface of the cylindrical canister  95  funnel area  107  and has a longitudinal center opening  111  wherethrough the nozzle end  108  of the cylindrical canister  95  is fitted. A seal  112  is provides between the nozzle end  108  and plug hole  111  to prohibit a flow of elastomeric material up the cylindrical canister  95  during vacuum forming operations. 
     The nozzle end  108  of the cylindrical canister  95  includes seal  112  and functions as a seat for the needle valve  100  head end  103  that is shown as having a cone shape, with the cone point to travel into the cylindrical canister  95  nozzle end until the slope of the head end  103  contacts the edge of the nozzle end  108 , sealing off flow. Which head end  103  travel is provided when the needle valve body  101  is moved up and down by lifting or lowering the valve body lower end  102 . In practice, for example, a servo motor operating a piston that connects to the valve body lower end  102  can provide for needle valve movement, opening and closing the cylindrical canister to a flow of elastomeric materials out from the nozzle end  108 , as set out herein below. 
     The cylindrical canister  95  is to receive a mixture of elastomeric constituents that, after mixing outside of the vacuum forming apparatus, is passed through a pouring head  116 , as shown in  FIG. 9B , and into the cylindrical canister  95 . Which pouring head  116  has a funnel shaped pouring end that is an inwardly sloping cone section that connects to a cylindrical nozzle end  117 . Shown in  FIG. 9A , the cylindrical housing top end  95   b  is ported to open through a pouring seat  118  that has an inwardly sloping cone shaped section  119  to receive and seal at seal  120  against the wall of the pouring head  116  inwardly sloping cone section. 
     To prepare the vacuum forming apparatus  90  to form a transport tire, the cover  90  is lowered, as illustrated by arrows B, onto the vacuum forming apparatus top plate  91 , sealing thereover at seal  121 , and passes along side of the surface  95   a  of the cylindrical canister  95 , with a seal  127  fitted between the cylindrical canister  95  surface  95   a  and the edge of the center hole  89   a  of the cover  89 , for containing the area under the cover. With the cover  89  maintained in place, to prepare for casting, pouring head  116  is lowered into the pouring seat  118  as illustrated by arrow C, and the needle valve is moved upwardly, as illustrated at arrow D, to close the nozzle end  108 . Thereafter, as shown in  FIG. 9B , a measured amount of an elastomeric mix of constituents  126  is poured into the cylindrical canister  95  through the pouring seat  118 , with an operator observing the canister filling through a sight glass  122  mounted in the surface  95   a  of the cylindrical canister. Prior to which pouring, a deep vacuum source is connected to cylindrical canister port  125  that is fitted into the side of the cylindrical canister, proximate to the top end thereon, and a low level vacuum source is connected to the cover port  97  fitted through the cover  89 , completing preparation of the vacuum forming apparatus  90  to receive a flow of elastomeric material into the cylindrical canister  95 , as illustrated in  FIG. 9B . Which elastomeric material is a mixture of constituents that are combined outside of the mold for pouring into the cylindrical canister  95 . The preferred constituents are a liquid isocyanate and a liquid poly, respectively, that are selected to form, when combined and cured, an elastomer having a desired hardness or derometer for an automobile or like transport tire. 
       FIG. 9B  is a view like  FIG. 9   a  and additionally shows the pouring head  116  as having been seated in the pouring seat  118  with a urethane pour  126 , as shown by arrow E, being poured through the open end of which pouring head, flowing into the cylindrical canister, to fill the canister from the nozzle end  108  up. During which canister filling a deep vacuum, arrow F, is pulled through the cylindrical canister  95  port  125 , pulling air out of the elastomeric materials mixture that was entrapped therein during the elastomeric material constituents mixing, as shown by arrows G that travels through the cylindrical canister port  125 . During which canister filling, an operator views the filling through the sight glass  122 . Further, in preparation for the vacuum forming of a transport tire within the vacuum forming apparatus  90 , a low level vacuum, shown as arrow H, is pulled through the cover port  97 , pulling air, shown as arrows I, out of the mold cavity and the area under the cover  89 . 
       FIG. 9C  is a view like that of  FIG. 9B  and additionally shows a desired volume of elastomeric material mix as having been poured into the cylindrical canister  95 . Whereafter, the high level vacuum is removed from the canister port  125  that is opened to atmosphere, illustrated by arrow J, allowing an inlet air flow shown as arrows K, in through the canister port  125 . At which port  125  opening, the needle valve is opened, allowing for a flow of the elastomeric material mix  126 , that has had essentially all the air removed therefrom, to flow across the inverted cone shaped end  103  of the needle valve  100 . Which elastomeric material mix  126  flow is shown as just proceeding out from the nozzle end  108  and passing under the plug  110  and above the surface of the top of the bottom bead alignment plate  92   b , to flow into the annular mold cavity and through the core  75  of plies, belts and beads therein, as shown in  FIG. 9D . 
       FIG. 9D  is a view like that of  FIG. 9C  and additionally shows the elastomeric materials pour as having passed through the needle valve  100  and is distributed throughout the mold cavity that is the annular area between the inner and outer molds that contains the core  75  of plies, belts and beads, forming the transport tire  130 , as shown in  FIG. 11 , and the needle valve  100  is closed prior to allowing air within the canister  95  to travel out of the nozzle end  108  across the surface of the needle valve head end  103 . Which elastomeric material is shown as having filled the cavity and is just passing up along the space the cylindrical canister  95  outer surface  95   a  and the walls of the center openings  91   a  and  94  of the vacuum forming apparatus top plate  91  and the top bead alignment plate  92   a , respectively. Which travel of the elastomeric material is in response to the low level vacuum, shown as arrow H, that is being pulled through the cover vacuum port  97 , with air ahead of the elastomeric material flow, shown as arrows I, being pulled toward the cover port  97  and exhausting through the cover vacuum port  97 . The cylindrical canister  95  port remains open, shown as arrow J, to ambient air during which elastomeric material flow through the cavity between the inner and outer molds as air is exhausted from beneath the cover  89  through the port  97 . Whereafter, the cover  89  is lifted off of the outer mold top  88  and the outer mold is broken apart to remove the finished tire therefrom. Which finished tire is like the tire  130  shown in  FIG. 11  that includes the core  75  of  FIG. 10 . 
       FIG. 12  shows a block flow schematic of a summary of the steps performed in forming an elastomeric tire utilizing the vacuum forming apparatus  90  as described above. Blocks  201  and  202  illustrate the formation of the core of plies, belts and beads on a mandrel component of a inner mold and the fitting of an outer mold thereto, forming a mold with the core occupying an annular area between the inner and outer molds. In which fitting together seals are positioned between the inner and outer mold segments to provide an air tight pathway through the annular area wherein the transport tire core  75  is maintained. For a vacuum forming apparatus  90 , as illustrated by block  202  and described above, a dome shaped cover is fitted over the outer mold top surface, engaging seals therebetween and the cylindrical cannister is fitted into center opening through the cover and connected inner and outer molds, sealing to the cover hole edges and at the outer mold top, providing a flow path from a needle valve end of the canister into the annular area containing the core to exit alongside the cannister into the area under the cover. Illustrated by block  203 , the pouring head has been fitted into the canister top end and, as illustrated by block  204 , the tapered head end of the needle valve has been moved into sealing engagement with the end of the canister discharge tube sealing off flow therethrough. So arranged, as high vacuum that is at least ninety six (96) percent is pulled through a canister port, pulling air out from the canister, as illustrated by block  205 , and a low level vacuum of at least eighty five (85) percent, and not greater than ninety five (95) percent, is pulled through a port through the cover, pulling air out from beneath the cover and the mold, as illustrate by block  206 . Thereafter, an elastomeric material that has been recently mixed from constituents is poured through the canister top, as illustrated by block  207 , with the high level vacuum to remove air from the elastomeric material mixture. When a desired volume or weight of elastomeric material has been poured into the canister, the high level vacuum is ended, as illustrated by block  208 , and the canister is opened to atmosphere. Simultaneously to opening the canister to atmosphere the needle valve is opened, as illustrated by block  209 , and the elastomeric material is passed into the mold annular area, traveling through the core, with the needle valve closed prior to a passage of air from the canister following the elastomeric material. An operator seeing elastomeric material venting from the mold top plate closes the needle valve, as illustrated by block  210 , if it has not already been closed to prevent air passage, and ends the low vacuum draw through the cover port, as illustrated by block  211 . The newly formed transport tire is allowed to cool and cure in the mold, as illustrated by block  212 , and then the mold is broken open and the transport tire removed, as illustrated by block  213 . 
     While preferred embodiments of our invention in a vacuum forming apparatus for forming a tire in a single operation, have been shown and described herein, it should be understood that variations and changes are possible to the apparatus and method for its use in the formation of the described tire, and the materials used, without departing from the subject matter coming within the scope of the following claims, and a reasonable equivalency thereof, which claims we regard as our invention.