Patent Description:
More particularly, the invention is intended for building green tyres, to be subsequently subjected to a vulcanisation cycle for obtaining the final product.

A tyre for vehicle wheels generally comprises a carcass structure comprising at least one carcass ply having respectively opposite ends engaged with respective anchoring annular structures, integrated in the zones normally identified with the name "beads", having an internal diameter substantially corresponding to a so-called "fitting diameter" of the tyre on a respective mounting rim.

The carcass structure is associated with a crown structure which can comprise one or more belt layers, situated in radial superimposition with respect to each other and with respect to the carcass ply, having textile or metallic reinforcement cords with cross orientation and/or substantially parallel to the circumferential extension direction of the tyre (at <NUM> degrees). In radially outer position with respect to the belt layers, a tread band is applied, also made of elastomeric material like other semifinished products constituting the tyre.

Respective sidewalls made of elastomeric material are applied in axially outer position on the lateral surfaces of the carcass structure, each extended from one of the lateral edges of the tread band up to the respective anchoring annular structure to the beads. In the tyres of "tubeless" type, an air impermeable covering layer, usually termed "liner", covers the internal surfaces of the tyre.

Following the building of the green tyre actuated by assembly of respective components, a treatment of moulding and vulcanisation is generally executed aimed to determine the structural stabilisation of the tyre by cross-linking the elastomeric compositions as well as to impart on the same, if requested, a desired tread design and possible distinctive graphic marks at the sidewalls of the tyre.

With the term "elastomeric material" it is intended to indicate a composition comprising at least one elastomeric polymer and at least one reinforcement filler. Preferably, such composition also comprises additives such as, for example, a cross-linking agent and/or a plasticising agent. Due to the presence of the cross-linking agent, by heating such material it can be cross-linked, so as to form the final manufactured product.

By "tyre for two-wheel vehicles", in particular motorcycles, it is intended a tyre whose curvature ratio is approximately comprised between about <NUM> and about <NUM>.

By "curvature ratio" relative to a tyre (or to a portion thereof) it is intended the ratio between the distance of the radially outer point of the tread band (or of the external surface) of the line passing through the laterally opposite ends of the tread itself (or of the external surface itself), measured on a radial plane of the tyre (or of said portion thereof), and the distance measured along the chord of the tyre (or of a portion thereof) between said ends.

By "curvature ratio" relative to a forming drum it is intended the ratio between the distance of the radially outer point of the external surface of the drum from the line passing through the laterally opposite ends of the drum itself, measured on a radial plane of the drum, and the distance measured along the chord of the drum between said ends. The terms "radial" and "axial" and the expressions "radially inner/outer" and "axially inner/outer" are used with reference to the radial direction of the forming drum used / of the tyre (i.e. to a direction perpendicular to the rotation axis of the aforesaid forming drum / tyre) and to the axial direction of the forming support used / of the tyre (i.e. to a direction parallel to the rotation axis of the aforesaid forming drum / tyre). The terms "circumferential" and "circumferentially" are instead used with reference to the annular extension of the aforesaid forming support / tyre.

A plane with respect to a forming drum or to a tyre is defined "radial" when it contains the rotation axis of the forming drum or of the tyre, respectively.

By "elementary semifinished product" it is intended a continuous elongated element made of elastomeric material. Preferably such continuous elongated element can comprise one or more textile and/or metallic and/or hybrid cords. Preferably such continuous elongated element can be cut to size.

By "component" or "structural component" of a tyre it is intended any one portion thereof capable of carrying out its own function, or a part thereof. Components of the tyre include for example the liner, the under-liner, the sidewall inserts, the bead cores, the filler inserts, the anti-abrasive elements, the sidewalls, the carcass ply/plies, the belt layer/layers, the tread band, the under-layer of the tread band, the under-belt inserts etc., or a part thereof.

The carcass structure, generally in sleeve form, and the crown structure are generally made separately from each other in respective work stations, in order to be mutually assembled together at a later time.

Toroidal forming drums provided with inserts which forms axially external annular rings are known, for example, by <CIT> and <CIT>.

The document <CIT> in the name of the same Applicant, describes a toroidal forming drum which is expanded within a shaped carcass sleeve, in order to support the carcass sleeve against an abutment surface present outside the forming drum. An elementary semifinished product is applied around the shaped carcass sleeve, pressing said elementary semifinished product towards the abutment surface. The abutment surface has circumferential rows of solid portions alternated with empty portions. The solid portions, arranged along axially opposite circumferential edges of the abutment surface, have a transverse size comprised between <NUM>% and <NUM>% of a transverse size presented by the solid portions arranged in proximity to an axial middle line plane of the abutment surface.

The document <CIT> in the name of the same Applicant, describes a forming drum comprising consecutive sectors that are radially movable between a contracted condition and an expanded condition in which the sectors are radially moved away from a geometric axis in order to define a radially outer abutment surface. Each sector has circumferentially opposite coupling portions, each comprising circumferential projections alternated with circumferential cavities. The projections of each sector are slidably engaged in the respective cavities of circumferentially adjacent sectors. From at least one of the projections, at least one support wing extends which has a first side and a second side, respectively opposite. The first side coincides with a portion of the abutment surface and the second side at least partially surmounts one of the projections that belong to an adjacent sector.

According to the Applicant the aforesaid production systems of the type illustrated in the documents <CIT> and <CIT>, in which the crown structure is directly made on the carcass structure while the latter is supported by a forming drum, also usable for the purpose of attaining the carcass structure, or internally couplable to the previously-formed carcass structure, allow improving the quality of the product.

The Applicant has nevertheless observed that the aforesaid forming drums are not well adapted for sustaining mechanical stresses of relatively high value. For example, in the production processes which provide for making the carcass structure directly on the forming drum, the application of the anchoring annular structures and/or of other components involves the transmission of relatively high axial thrusts against the axially opposite edges of the forming drum. The presence of surface discontinuities in these zones tends to determine the onset of high localized pressures, with consequent risks of early wear and/or breakage.

The Applicant has also observed that if the production requirements require frequent changes of the geometric and structural characteristics of the tyres under production, the need to arrange and manage a high quantity of forming drums, each adapted for a specific tyre size to be attained, involves difficulties both regarding logistics for managing the necessary storage spaces for housing the drums, and costs due to the high investments required for making the single drums.

The Applicant has perceived that by generating substantially continuous abutment surfaces on the axially more external portions of the forming drum, by respective auxiliary elements removably engaged with the sectors, it is possible to simplify the application of the components of the tyre being processed and at the same time obtain an easy geometric and size adaptability of the drum itself.

More particularly, the Applicant has finally found that by arranging axially opposite auxiliary elements or inserts in proximity to the axially opposite edges of each sector of the drum, it is possible to form elements having substantially continuous annular surfaces extending along the axially opposite edges of the forming drum, simplifying the deposition of the components of the tyre being processed on the drum itself and increasing the structural strength of the latter with respect to stresses induced during processing. The geometric and size characteristics of the inserts can also be advantageously selected depending on the requirements, so as to limit or eliminate the risk of formation of undesired air sacks between the various components deposited on the drum.

In accordance with one aspect, the invention relates to a process for building tyres according to independent claim <NUM>.

In accordance with a further aspect, the invention relates to an apparatus for building tyres for vehicle according to independent claim <NUM>.

The Applicant deems that the presence of annular elements, i.e. elements having an annular surface with substantially continuous extension, can facilitate the application of the structural components in proximity to the axially opposite edges of the forming drum. In particular, the annular elements defined by the inserts in the operative position are adapted to effectively sustaining stresses, even considerable ones, preserving the structural integrity of the forming drum during the application of high axial thrusts required for the purpose of the application of specific components, such as for example the annular reinforcement structures. In addition, the Applicant deems that the possibility of contraction and expansion of the forming drum is not compromised if each of the annular elements is composed of a plurality of inserts, each oscillatably constrained to one of the sectors. The presence of the annular elements formed by movable inserts also allows an easy adaptation of the drum for processing tyres which are structurally and/or geometrically different from each other. The inserts are in fact adapted to be easily substituted with inserts of different size or geometry, in order to modify the shaping of the drum as a function of the production requirements. The making of the inserts for obtaining annular elements of different shapes and sizes requires considerably lower times and costs with respect to those required for making the entire drum, and also the storage spaces for the dismounted inserts are drastically reduced.

In at least one of the aforesaid aspects, the invention comprises one or more of the following preferred characteristics which are described hereinbelow.

Preferably, said inserts form a first series of inserts, in which after the removal of the first tyre being processed, the first series of inserts is removed from the sectors of the forming drum and substituted with inserts belong to a second series and having size different from the inserts of the first series, before applying, on the deposition surface of the forming drum, at least one component of a second tyre being processed.

The availability of different series of inserts allows an easy adaptation of the geometric and size characteristics of the forming drum as a function of the production requirements, facilitating the production flexibility also in the production of batches of different tyres.

Preferably, said inserts are brought to the operative position starting from a rest position in which they extend each transverse to a circumferential direction that is concentric with respect to the geometric axis of the forming drum.

The orientation of the inserts according to directions transverse to the circumferential direction allows the diameter contraction of the forming drum in the absence of mechanical interferences or jamming between circumferentially contiguous inserts.

Preferably, in the operative position, the inserts each arranged along axially opposite edges of the forming drum extend, one on the continuation of the other, along a circumferential direction that is concentric with respect to the geometric axis of the forming drum.

The surface continuity of the annular elements formed by the inserts in the operative position is therefore facilitated.

Preferably, in the operative position, respective circumferentially opposite terminal walls of each insert are mated each with one of the terminal walls of a circumferentially adjacent insert.

Preferably, each insert rotates around a rotation axis axially extending through a lying plane of the respective axial end edge of the central body.

According to the Applicant, the rotatable connection represents an optimal solution, structurally simple and functionally reliable, in order to facilitate the movement of the inserts between the rest position and the operative position.

Preferably, each insert is elastically thrust towards the operative position.

The structure of the forming drum is therefore simplified, rendering the use of levers or other drive systems not necessary for causing the movement of the inserts towards the operative position.

Preferably, during the contraction of the forming drum, each insert is thrust towards the rest position upon action of a projection belonging to an adjacent sector, acting against a cam portion carried by the insert itself.

Preferably, said at least one component is applied by an axial thrust action against the axially opposite edges of the forming drum. Preferably, each insert has an axially inner wall acting axially in abutment relationship against the central body in order to oppose the axial thrust action transmitted to the forming drum during the application of the component.

Preferably, provision is also made for the action of radially contracting the forming drum after the application of said at least one component, and removing the first tyre being processed from the forming drum. Preferably, said radially outer deposition surface is substantially continuous.

Preferably, each sector has a central body carrying circumferentially opposite coupling portions.

Preferably, the coupling portions each comprise circumferential projections alternated with circumferential cavities.

Preferably, the projections of each sector are slidably engaged in the respective cavities of circumferentially adjacent sectors.

Preferably, the central body of each sector is axially delimited between two opposite axial end edges.

Preferably, said axial end edges are mutually spaced to an extent smaller than the overall axial size of the deposition surface.

Preferably, said axial end edges are each spaced from one of the axially opposite edges of the forming drum.

Preferably, multiple series of inserts are provided that have respectively different sizes, each series of inserts being separately and selectively engageable with the central bodies of the sectors in order to confer a predetermined geometric shaping to the forming drum. Preferably, said annular elements define axially outer portions of the deposition surface.

The application of semifinished products and/or components is therefore simplified since, due to the annular elements, the surface discontinuities can be eliminated or considerably reduced, such discontinuities typically due to the alternation of projections and cavities which, especially in the axially outer zones of the drum, tend to obstruct a correct application of the semifinished products.

Preferably, said inserts are movable towards the operative position starting from a rest position in which they extend each transverse to a circumferential direction that is concentric with respect to the geometric axis of the forming drum.

Preferably, each insert has an elongated curvilinear shaping in a substantially circumferential direction.

Preferably, in the operative position, each insert extends along a circumferential direction that is concentric with said geometric axis. Preferably, in the operative position, the inserts each arranged along the axially opposite edges of the forming drum extend, one on the continuation of the other, along a circumferential direction that is concentric with respect to the geometric axis of the forming drum. Preferably, each insert is rotatably engaged with the central body by a pin axially extending through the respective axial end edge of the central body.

Preferably, each insert is removably connected to the pin by a fixing screw coaxially engaged with the pin itself.

Each of the inserts is therefore adapted to be easily substituted by simple removal of the fixing screw.

Preferably, each insert is elastically thrust towards the operative position by at least one spring operating between the central body of the respective sector and the insert itself.

Preferably, the spring has one end constrained to an arm radially projecting from the pin.

The return springs and the pins can therefore remain constrained to the respective sectors during the removal of the inserts, simplifying the substitution thereof without it being necessary to provide for the dismounting and remounting of the pins and springs.

Preferably, the arm is situated in a position radially inside one of said coupling portions next to one of the projections.

Preferably, each insert has an axially inner wall directed towards the central body of the respective sector.

Preferably, said axially inner wall is substantially flat.

Preferably, said axially inner wall acts in abutment relationship against an abutment surface carried by the central body of the respective sector at the respective axial end edge.

Preferably, said abutment surface is substantially flat.

Preferably, the axially inner wall of the insert and the abutment surface slidably mate in a plane orthogonal to the geometric axis of the forming drum.

Wide surface of mutual contact between the inserts and the sectors are thus attained, increasing the structural strength of the assembly even in relation to the stresses induced during processing, for example during the approaching of the anchoring annular structures to the forming drum and/or the turning up of the ply/plies for the purpose of building the carcass structure.

Preferably, each insert has a curved longitudinal extension between at least two terminal walls that are circumferentially opposite each other. Preferably, in the operative position, the terminal walls of each insert are each approached with one of the terminal walls of a circumferentially adjacent insert.

Preferably, in the operative position, the terminal walls of each insert mate each with one of the terminal walls of a circumferentially adjacent insert.

Preferably, at least in the operative position, the terminal walls of each insert are each parallel to one of the terminal walls of a circumferentially adjacent insert.

Preferably, said terminal walls are arranged according to an extension that is tilted with respect to a radial direction at the geometric axis of the forming drum.

Preferably, in the operative position, the terminal walls form an angle approximately comprised between <NUM>° and <NUM>° with respect to a radial direction at the geometric axis of the forming drum.

Preferably, each insert has a cam portion made in the shape of a lateral projection arranged in proximity to one of the circumferentially opposite terminal walls of the insert itself.

Preferably, each insert has a cam portion having a shaping complementary to a space existing between axially outer projections belonging to two circumferentially adjacent sectors.

A greater continuity is thus conferred to the deposition surface of the forming drum, especially in the zones close to the axial end edges of the central body.

Preferably, each insert has a cam portion configured for interacting against the central body of one of the circumferentially adjacent sectors.

The synchronised movement of the inserts towards the rest position is therefore obtained following the contraction of the drum, without requiring the use of levers and/or other additional drive systems. Preferably, said cam portion is made in the shape of a lateral projection arranged in proximity to one of the circumferentially opposite terminal walls of the insert, in order to interact against one of the projections carried by the sector circumferentially adjacent to that carrying the insert itself.

Preferably, at least in the operative position, the cam portion of each insert is approached to a radially inner surface of one of the axially outer projections belonging to the central body of the sector adjacent to that carrying the insert itself.

When the drum is contracted starting from the expanded condition, the action of the projections on the cam portions of the inserts assists the rotation thereof around the respective pins, opposing the action of the springs.

The driving of the synchronised movement of the inserts is therefore effectively attained due to the action of contraction and expansion of the forming drum, without requiring the use of levers and/or other additional drive systems.

Further characteristics and advantages will be clearer from the detailed description of a preferred but not exclusive embodiment of a process and an apparatus for building tyres for vehicle wheels, in accordance with the present invention.

Such description will be set forth hereinbelow with reference to the enclosed drawings, provided only as a non-limiting example, in which:.

With reference to the abovementioned figures, reference number <NUM> overall indicates an apparatus for building tyres for vehicle wheels. The apparatus <NUM> is arranged to actuate a building process in accordance with the present invention.

The apparatus <NUM> is set for attaining tyres <NUM> (<FIG>) essentially comprising at least one carcass ply <NUM> preferably internally covered by a layer of impermeable elastomeric material or so-called liner <NUM>. Two anchoring annular structures <NUM>, each comprising a so-called bead core 5a preferably carrying an elastomeric filler 5b in radially outer position, are engaged with respective end flaps 3a of the carcass ply/plies <NUM>. The anchoring annular structures <NUM> are integrated in proximity to zones normally identified with the name of "beads" <NUM>, at which the engagement between the tyre <NUM> and a respective mounting rim (not depicted) usually occurs.

A belt structure <NUM> is circumferentially applied around the carcass ply/plies <NUM>, and a tread band <NUM> is circumferentially superimposed on the belt structure <NUM>. Two sidewalls <NUM>, each extended from the corresponding bead <NUM> to a corresponding lateral edge of the tread band <NUM>, are applied in laterally opposite positions on the carcass ply/plies <NUM>.

The apparatus <NUM> comprises a carcass building line <NUM> having one or more building stations <NUM> where, e.g. according to known manners, the making of a carcass sleeve <NUM> having substantially cylindrical shaping is executed. The carcass building line <NUM> leads to a shaping station <NUM> in which the carcass sleeve <NUM> is shaped according to a toroidal configuration, for example as described in the abovementioned document <CIT>.

The carcass sleeve <NUM> comprises said at least one carcass ply <NUM>, preferably internally covered by the liner <NUM>. If necessary, the carcass sleeve <NUM> can also comprise the sidewalls <NUM> or first portions thereof, each extended starting from a respective bead <NUM>.

In the shaping station <NUM>, a substantially rigid and expandable toroidal forming drum <NUM> is preferably removably engaged.

Application devices <NUM> operate in proximity to the shaping station <NUM> for applying the previously-obtained carcass sleeve <NUM>, and/or other components of the tyre <NUM> being processed, on a deposition surface S presented outside the forming drum <NUM>. For example, the same carcass sleeve <NUM> can be directly made on the forming drum <NUM> by applying the single components thereof (liner, carcass ply/plies, bead cores etc.) on the deposition surface S.

The association of the anchoring annular structures <NUM> with the carcass structure <NUM> can be executed at the carcass building line <NUM>, as is for example provided in the document <CIT>. In a possible embodiment variant, the association of the anchoring annular structures <NUM> with the carcass structure <NUM> can be executed at the shaping station <NUM>, after the carcass sleeve <NUM> lacking anchoring annular structures has been arranged on the forming drum <NUM>.

The forming drum <NUM> can be removably engaged with the same shaping station <NUM> with the aid of at least one robotic arm <NUM>, which is also adapted for its transfer to possible additional work stations <NUM>. The forming drum <NUM> is expandable between a radially contract condition (<FIG> and <FIG>), and a radially expanded condition (<FIG>, <FIG>, <FIG>, <FIG>, <FIG>). For such purpose, the forming drum <NUM> comprises a plurality of sectors <NUM> circumferentially distributed around a central shaft <NUM> (<FIG>) coaxial with a geometric rotation axis X-X of the drum itself.

The sectors <NUM> are movable upon action of radial movement devices, preferably simultaneously with respect to each other, from the aforesaid contracted condition in which they are radially approached to the central shaft <NUM>, to the expanded condition in which said sectors <NUM> are radially moved away from the central shaft <NUM>, i.e. from the geometric axis X-X. The radial movement devices are not illustrated in detail since they can be attained in any known manner, for example as indicated in <CIT> or in <CIT>.

In the expanded condition, the assembly of the sectors <NUM> of the forming drum <NUM> defines, along the circumferential extension thereof, the deposition surface S. The deposition surface S is toroidally shaped according to the internal configuration which at least one part of the carcass sleeve <NUM> must take on upon completed shaping. More in detail, it can be preferably provided that the deposition surface S of the forming drum <NUM> in the expanded condition has a curvature ratio comprised between about <NUM> and about <NUM>, typically adapted for making tyres for motorcycles or other two-wheel vehicles. If necessary, curvature ratios can nevertheless be employed with values lower than those indicated above, for example suitable for the production of car or truck tyres.

As is better illustrated in <FIG>, each of the sectors <NUM> has a central body <NUM>, axially delimited between two opposite axial end edges <NUM>, mutually spaced to an extent W1 smaller than the overall axial size W2 of the deposition surface S. Preferably, the axial end edges <NUM> of the central body <NUM> are each spaced by one of the axially opposite edges <NUM> of the forming drum <NUM>.

The central body <NUM> of each sector <NUM> carries a first coupling portion 18a and a second coupling portion 18b, circumferentially opposite and preferably interconnected by an intermediate portion 18c which has, at least on the deposition surface S, a main extension direction parallel to a radial plane of the forming drum <NUM>. Each of the coupling portions 18a, 18b has a plurality of elongated projections <NUM> extended in a circumferential direction from the intermediate portion 18c, alternated with respective circumferentially elongated cavities <NUM>.

In a same sector <NUM>, the projections <NUM> belonging to one of the coupling portions, for example the first coupling portion 18a, are offset with respect to the projections <NUM> of the other coupling portion 18b. The axially more external projections <NUM> of one of the coupling portions, for example of the first coupling portion 18a, define the axial end edges <NUM> of the central body <NUM> of the respective sector <NUM>. The projections <NUM> of each sector <NUM> are slidably engaged in the respective cavities <NUM> of the circumferentially adjacent sectors <NUM>, and are adapted to slide in the cavities themselves in order to support the expansion and contraction movements of the forming drum <NUM>.

In the contracted condition, the projections <NUM> of each sector <NUM> penetrate into the respective cavities <NUM> up to touching or nearly touching the intermediate portion 18c of the adjacent sector <NUM> (<FIG> and <FIG>). More particularly, in the contracted condition the projections <NUM> are inserted in the respective cavities <NUM> to an extent at least equal to <NUM>% of their length.

In the expanded condition, the projections <NUM> are extracted from the cavities <NUM> to an extent at least equal to <NUM>% of their length, as is better visible in <FIG>, <FIG> and <FIG>.

Coupled with the central body <NUM> of each sector <NUM> is a pair of interchangeable inserts <NUM>, each removably engaged at one of the axial end edges <NUM> of the central body <NUM> itself.

Each insert <NUM> has an axially inner wall <NUM> directed towards the central body <NUM> of the respective sector <NUM>. The axially inner wall <NUM>, preferably flat, acts in axial abutment relationship against an abutment surface 24a, also preferably flat, carried by the central body <NUM> of the respective sector <NUM> at the respective axial end edge <NUM>. The axially inner wall <NUM> of the insert <NUM> and the abutment surface 24a slidably mate in a plane orthogonal to the geometric axis X-X of the forming drum <NUM>.

Each insert <NUM> extends preferably according to a curved longitudinal extension between at least two circumferentially opposite terminal walls <NUM>. More particularly, the insert <NUM> has an elongated curvilinear shaping in a substantially circumferential direction. The insert <NUM> is rotatably engaged with the central body <NUM> by a pin <NUM> around a respective rotation axis Y-Y arranged perpendicular to the axially inner wall <NUM> and axially extending through a lying plane containing the respective axial end edge <NUM> of the central body itself. Preferably, as is better visible in <FIG>, the pin <NUM> is rotatably engaged through one of the axially more external projections <NUM> of the first coupling portion 18a, which define the axial end edges <NUM> of the respective central body <NUM>. A fixing screw <NUM> can be engaged through the insert <NUM> and engaged via screwing coaxially in the pin <NUM>, in order to fix the latter to the insert <NUM> itself, against its axially inner wall <NUM> directed towards the central body <NUM>.

Preferably, each insert <NUM> is operatively associated with at least one spring <NUM>, e.g. a helical traction spring, operating between the insert itself and the central body <NUM> of the respective sector <NUM>. The spring <NUM> has a first end constrained to the central body <NUM>, and a second end operating on an arm <NUM> radially projecting from the pin <NUM> of the respective insert <NUM>. More particularly, the arm <NUM> is preferably situated in radially inner position with respect to the central body <NUM>, more precisely at the first coupling portion 18a next to one of the axially more external projections <NUM>, on the side of the latter opposite the axial end edge <NUM> of the central body <NUM>. In the illustrated example, the arm <NUM> carries a terminal screw <NUM> projecting on the continuation of the arm <NUM> itself in order to engage the second end of the spring <NUM>.

Each insert <NUM> is movable around the rotation axis Y-Y of the respective pin <NUM>, preferably together with the latter, between a rest position in which it extends transverse to a circumferential direction C-C (<FIG>) that is concentric with respect to the geometric axis X-X of the forming drum <NUM>, and an operative position in which it extends along such circumferential direction C-C (<FIG>).

The operative position of the inserts <NUM> corresponds with the expanded condition of the forming drum <NUM>. As is visible from <FIG> and <FIG>, in this situation the inserts <NUM> constrained to the respectively opposite axial end edges <NUM> of each sector <NUM> each extend on the continuation of the inserts <NUM> belonging to the circumferentially adjacent sectors <NUM>. The inserts <NUM>, each arranged along axially opposite edges <NUM> of the forming drum <NUM>, extend one on the continuation of the other along the circumferential direction C-C that is concentric with respect to the geometric axis X-X. More particularly, each insert <NUM> can have the respective terminal walls <NUM> approached, preferably mating and parallel, each with one of the terminal walls <NUM> of the circumferentially adjacent insert <NUM>, in favour of the surface continuity of the assembly. The terminal walls <NUM> of each insert <NUM> can be arranged each according to an extension that is tilted with respect to a radial direction R at the geometric axis X-X of the forming drum <NUM> and incident with the terminal wall itself. Preferably, in the operative position each of the terminal walls <NUM> forms an angle approximately comprised between <NUM>° and <NUM>°, more preferably between <NUM>° and <NUM>°, with respect to the radial direction R at the geometric axis X-X incident with the terminal wall itself.

In the operative position, the assembly of the inserts <NUM> forms two substantially continuous annular elements <NUM>, each extended along one of the axially opposite edges <NUM> of the forming drum <NUM>. Such annular elements <NUM> define axially outer portions of the deposition surface S, positioned so as to provide an abutment for the carcass sleeve <NUM> of the tyre <NUM> being processed, approximately in the zones of the beads <NUM>.

Following the contraction of the forming drum <NUM> starting from the expanded condition, a mutual approaching is caused of the sectors <NUM> in the circumferential direction C-C, with a progressive sliding of the projections <NUM> towards the interior of the respective cavities <NUM>. During the contraction of the forming drum <NUM> towards the contracted condition, the terminal walls <NUM> of the inserts <NUM> are adapted to slidably interact against each other, so as to facilitate a progressive rotation of the inserts themselves towards the rest position, opposing the action of the springs <NUM> which tend to elastically bring the inserts <NUM> back, each towards the respective operative position.

In addition or as an alternative to the interaction between the terminal walls <NUM>, each insert <NUM> can have a cam portion <NUM>, preferably made in the form of a lateral projection arranged in proximity to one of the circumferentially opposite terminal walls <NUM> of the insert <NUM>. The cam portion <NUM> can have a shaping complementary to a space existing between the axially outer projections <NUM> belonging to two circumferentially adjacent sectors <NUM>, so as to confer greater continuity to the deposition surface S in the zones close to the axial end edges <NUM> of the central body <NUM>.

Each cam portion <NUM> can be arranged to interact against the central body <NUM> of the sector <NUM> circumferentially adjacent to that carrying the insert <NUM> itself, in order to facilitate the movement of the insert itself towards the rest position up to reaching the contracted condition of the forming drum <NUM>. For example, the cam portion <NUM> can interact against one of the projections <NUM> carried by the circumferentially adjacent sector <NUM>. More particularly, at least in the operative position, the cam portion <NUM> of each insert <NUM> is approached, preferably in abutment relationship, to a radially inner surface of one of the axially more external projections <NUM> belonging to the central body <NUM> of the sector <NUM> adjacent to that carrying the insert itself. When the forming drum <NUM> is contracted starting from the expanded condition, the action of the projections <NUM> on the cam portions <NUM> assists the rotation thereof around the rotation axes Y-Y defined by the respective pins <NUM>, opposing the action of the springs <NUM>, up to carrying them into the rest position upon reaching the contracted condition of the forming drum <NUM>.

For the purpose of building a tyre <NUM>, the forming drum <NUM> that was previously contracted, for example in order to allow the removal thereof from a previously-build tyre, is radially expanded from the contracted condition exemplified in <FIG>, to the expanded condition exemplified in <FIG>.

Simultaneously with the expansion of the forming drum <NUM> from the contracted condition to the expanded condition, the inserts <NUM>, initially retained in rest position due to the interaction between the central bodies <NUM> and the cam portions <NUM>, are returned by the respective springs <NUM> and rotate around the rotation axes Y-Y of the respective pins <NUM> up to taking on the operative position upon reaching the radially expanded condition of the forming drum <NUM>.

The annular elements <NUM> formed by the succession of the inserts <NUM> in the operative position contribute, together with the central bodies <NUM> of the sectors <NUM>, in order to define the deposition surface S in its entirety. Such deposition surface can be possibly defined, at least at the central bodies <NUM> of the sectors <NUM>, by an elastic membrane <NUM> represented in a dashed line in <FIG>, circumferentially extended around the forming drum <NUM>.

The forming drum <NUM> in the expanded condition is adapted to receive the carcass sleeve <NUM> and/or other components of the tyre <NUM> being processed, associated with the drum itself by the application devices <NUM>.

The application of several components of the tyre, for example the anchoring annular structures <NUM>, can require the transmission of axial thrust actions, also of considerable impact and/or size, at the axially opposite edges <NUM> of the forming drum <NUM>. On such matter, the cooperation between the axially inner walls <NUM> of the inserts <NUM> and the abutment surfaces 24a carried by the central body <NUM> of each sector <NUM> offers a wide contact surface, which is adapted for effectively distributing the stresses induced by the aforesaid axial thrust actions. The application of the components of the tyre <NUM> can be completed in the shaping station <NUM>. Alternatively, provision can be made such that the forming drum <NUM> carrying the carcass sleeve <NUM> and possible other additional components is removed from the shaping station <NUM> and transferred into one or more additional work stations <NUM> in order to execute the application of further components, such as the belt structure <NUM>, the tread band <NUM>, the sidewalls <NUM> and/or other items.

At the end of the building of at least one first tyre <NUM> being processed, the forming drum <NUM> is radially contracted in order to facilitate the removal of the same built tyre.

The inserts <NUM> of the forming drum <NUM> are easily dismountable from the respective central bodies <NUM> and substitutable with inserts <NUM> having different geometric and size characteristics, in order to adapt the forming drum <NUM> for the processing of tyres <NUM> having different structural characteristics. For such purpose, it is possible to act on the fixing screws <NUM> so to be able to remove and substitute the inserts <NUM>. Such operation can be conveniently executed without having to remove the pins <NUM>, the arms and/or the springs <NUM>.

Provision is preferably made such that a same forming drum <NUM> is coupled with a multiple series of inserts <NUM>. Each series of inserts <NUM> is separately and selectively engageable with the central bodies <NUM> of the sectors <NUM> in order to confer a predetermined geometric shaping to the forming drum <NUM>. In other words, the series of inserts <NUM> are selectively interchangeable in order to adapt the forming drum <NUM> to the processing of tyres <NUM> having different structural characteristics.

With reference to the enclosed drawings, the inserts <NUM> illustrated in <FIG> belong to a first series of inserts <NUM>. In the example of <FIG>, inserts are illustrated and marked with 23a which belong to a second series, engaged with the central body <NUM> of a respective sector <NUM> in place of the inserts <NUM> belonging to the first series. The inserts belonging to the second series 23a have geometric and size characteristics different from those of the inserts <NUM> belonging to the first series. More specifically, the inserts of the second series 23a have an axial extension Z2 and/or radial extension different with respect to that of the inserts <NUM> of the first series. In the illustrated example, the inserts of the second series 23a have an axial extension Z2 smaller than the axial extension Z1 of the inserts <NUM> of the first series. The engagement of the inserts belonging to the second series 23a in substitution of those of the first series therefore allows easily adapting the geometric and size characteristics of the forming drum <NUM> to the processing of carcass sleeves <NUM> in which the extension of the carcass ply/plies <NUM>, in the section comprised between the anchoring annular structures <NUM>, is smaller than that encounterable with the use of the inserts <NUM> belonging to the first series.

After a first tyre <NUM>, attained for example by employing the inserts <NUM> belonging to the first series, has been removed from the forming drum <NUM>, the first series of inserts <NUM> can if necessary be removed from the sectors <NUM> and substituted with the inserts of the second series 23a, before starting the application of the components of a second tyre <NUM> having different structural characteristics.

Claim 1:
Process for building tyres, comprising:
arranging an expandable toroidal forming drum (<NUM>), comprising circumferentially consecutive sectors (<NUM>) that are radially movable, each comprising a central body (<NUM>) and a pair of interchangeable inserts (<NUM>), each removably engaged at a respective axial end edge (<NUM>) of the central body (<NUM>);
expanding the forming drum (<NUM>) from a contracted condition in which said sectors (<NUM>) are moved close to a geometric rotation axis (X-X) of the forming drum (<NUM>), to an expanded condition in which the sectors (<NUM>) are radially moved away from said geometric axis (X-X) in order to define a radially outer deposition surface (S) extending between two axially opposite edges (<NUM>) of the forming drum (<NUM>);
applying, on the deposition surface (S) of the forming drum (<NUM>), at least one component of a first tyre (<NUM>) being processed;
characterised in that,
during the expansion of the forming drum (<NUM>), the inserts (<NUM>) of each sector (<NUM>) are moved with respect to the respective central bodies (<NUM>) by rotation around a rotation axis (Y-Y) axially extending through a lying plane of the respective axial end edge (<NUM>) of the central body (<NUM>), up to an operative position in which said inserts (<NUM>) extend each on the continuation of the inserts (<NUM>) belonging to the circumferentially adjacent sectors (<NUM>), in order to form annular elements (<NUM>) extending along the axially opposite edges (<NUM>) of the forming drum (<NUM>).